It was a nightmare!! All done before Christmas too.. hahaha. Actually finished before Thanksgiving. I am currently applying the cast on, and that is more of a nightmare. I have to get a dremel to start smoothing out the areas where there are grooves. Also, some areas are thicker than others.
This is my first build so it is more of a learning experience than anything. The Smooth-cast is such a pain in the a$$. The pot life is extremely fast. It is definitely going to take some time to make this look good. I only have a little over a month left on deployment now, so come Christmas time, whatever is finished I am going to just ship home so I can continue on it when I get back.
I feel like it should have gone the bondo route instead. Seems like it would have been easier to work with, but it produces more fumes than the smooth-cast. If anyone else decides to use smooth-cast i would highly recommend to use it in a very well ventilated area with a respirator on. I've tried sanding a bit here and there but very little material comes off. A dremel then sand paper is your best bet.
I will be posting more photos of my progress soon. I want to continue applying the smooth-cast until I have a thick enough layer to work with so I dont deteriorate the cardstock and be left with no template to work with.
The area around the ears was extremely difficult. And actually if I take a close up photo you can see that its not perfect. The smooth-cast dries thick depending on how much you apply to the area or how much it runs so the detailed areas are going to be difficult when it comes to using the dremel and sand paper.
