Real master chiefs Mk6 / ODST build with carbon and cold cast Ali

[realmasterchief]

Hey guys,

I thought it might be a good time to start a build thread so here it is.

The build is a bit different... The parts will be pep'ed as normal, but then I'm using the pep'ed armor pieces to make GRP moulds so I can recreate the parts in cold cast aluminium and carbon.... If it all goes well the result will be a suit of armor that looks like it's made of metal with some of the smaller pieces made from carbon.

work is currently underway on an ODST shoulder (not really MK6 but I like the look) so far I have completed the mould for the hinge and the top section just needs a bit more sanding before it's prepped for gel coat.

I turned out a hinge piece this evening from carbon but I'm having problems with air bubbles in the corners between the clear gel coat and the carbon cloth :-(

I'm thinking i may need to make a male version of my female mould so I can press the fabric into the corners??????

has anyone made pieces from carbon before? And if so any advice on how to avoid air bubbles on the smaller pieces???

pics to follow in the week

 

[Tetro]

seems like an awesome idea to me!
I didn't have the occasion to try aluminium and carbon so I wont be able to give any advice, but I hope you'll get some

 

[purpuk]

you could try pinholes in the corners and then pull the fabric in from the outside with fine wire until it sets and then pull hard and the wire only leaves a pinhole

 

[realmasterchief]

Ok, so it's been a month since I put the post up but here is some pics of what I was on about.
im still working on the mould for the top part of the shoulder and got a bit distracted by a Reach scout helmet

 

[realmasterchief]

 

[elementfx]

Try using a vac bag to suck the air out of it and form the carbon to the gear. I did my helmet that way and it came out amazing. there are a few types of setups you can use to make a vac bag but if you are spending the cash in the carbon then spend the doe in the tools to make it right. Basic unit pulls the air and excess resin out of the bag making an air tight seal. After about 2-4 hours of letting it sit with the vac unit on then you can let it sit for about 24-48 hours and the bag will rip right off. I know it may sound like it is easy but the first time you set up the unit will take about 5-6 hours if done right.