Hey all, I have a question that I hope someone can answer for me.

I am designing a case mod that is going to incorporate a gas mask on the front of the case. I would like to do one of two things to accomplish this.

I would like to mold a gas mask that I have and fiberglass that mold for the case panel.

-or-

I would like to sculpt the gas mask out of some sort of foam that will stand up to bondo so I can apply a layer or two of bondo to give it some rigidness.

My main problem for the first option is finding a casting material that will stand up to fiberglass, but that is still flexible enough to come off the gas mask. I have ask all the local hobby shops and they all know what I am talking about, but none of them can give me a product name or model. I assume I would need some sort of pour and mix 2 part foam product.

My problem with the second one is that I don't know what kind of foam I can buy that will hold up and not melt under fiberglass and or bondo.

If anyone has any suggestions or ideas that might help me I am all ears.

Thanks, and glad to be part of the community.

I have decided to use insulating foam and body filler instead of fiberglass. Easier to work with and much cheaper.

Ill post worklogs as I get them completed.

Quote: Originally Posted by cscheck I have decided to use insulating foam and body filler instead of fiberglass. Easier to work with and much cheaper. Ill post worklogs as I get them completed.

If you are planning to put this mask somewhere that flexes I would suggest you get some short strand reinforced fiberglass body filler. If its just bondo body filler it can crack if you flex it too much. Just a FYI. Good luck.

That was my initial thought. It is going on the front bezel so I wanted to use fiberglass, but I don't know what I could use to create my base out of.

I don't want to spend a lot of time carving and shaping a foam mock up only to have the fiberglass melt it down as soon as I apply it.

If you can give me a good idea of what kind of foam to buy, or a link to an online resource that would be awesome.

You could have used some Alginate to make a casting of the mask and then pour it with plaster. From there all you would have needed to do is lay down a few layers of fiberglass and resin and you would probably be all set to then use the short strand body filler to attach it to the case.

Quote: Originally Posted by FeRaL You could have used some Alginate to make a casting of the mask and then pour it with plaster. From there all you would have needed to do is lay down a few layers of fiberglass and resin and you would probably be all set to then use the short strand body filler to attach it to the case.

Thanks for that. I will be looking into Alginite today. Hopefully I will find that it is cheap and you don't have to buy 1000 gallons of it to place an order.

I think I am on the right track now. I have done plaster molding, but there is so much rigidity in this mask that plaster would not have worked without making it in 4 or 5 pieces. I think going from Alginite to plaster to fiberglass is the route for me.

Thanks!!!

Yeah I think that would be your best bet. It will probably also look better in the end. Post some pics when your done with it I'd like to see it.

Quote: Post some pics when your done with it I'd like to see it.

I will do that for sure. I am sure I will be back with more questions as this is my first casting project. I make no guarantees. I actually ordered the Alginate today and it should be here sometime next week.

Between now and then I gotta get my work area cleaned up.

Thanks for the help to all of you. I look forward to contributing my worklog and photos for the communities viewing pleasure. (Hopefully its pleasurable!)