Weapon making, Rondo alternative?

[Crossy71]

Hey guys sorta lost my cool with making my props a while bak but im getting bak in the saddle with something big.. The roadwarrior ma5b, i have the lo def version close to finish with rondo on the inside for strength, BUT... it warped on the front (barrel section) of the gun. I was wondering if there is any alternatives to rondo ive had a good search around but couldnt find anything.
I can remember a while bak seeing a post about using some sort of foam for the strength? All this made me think of was the expanding foam type but surely thats gonna distort even with a layer or two of resin on the outside my last prop was made of 110gsm card would i have to use something like a 200gsm type card for this foam process?

Many tanks in advance

 

[Sky Walker]

Smooth Cast is very strong and is applied the same way as rondo (slush casting)

 

[sandy1973]

I used smoothcast for my weapons build.

 

[Crossy71]

ok great thanks guys, is it the same consistancy as rondo (thick like Treacle) or is it nice and runny so it can easily get in everywere? Also u say very strong is it better than rondo or weaker?

 

[Crossy71]

Never mind, found jedistumpys video of casting his helmet. Looks pretty damn strong by the way he drops it and it bounces back (literally Haha)

 

[Sky Walker]

it is pretty runny... for lack of a better example: kinda like egg nog...

and it is a polyurithene plastic... so it is much stronger than rondo and less brittle

 

[Crossy71]

conserning the road warrior ma5b.. does the scaling take into count the extra length and width that the optional barrels in the 3d model take up? coz im building it to the preset size and the parts ive done so far appear smaller than i would think especially compared to my lo def version...