Project Monza-from die-cast to resin.

Hello everybody!
I visited this forum ages ago and now I decided to come back and show you the project I have been working on.
This is the college graduation project. At first I wanted to do a Opel Lotus Omega model kit. But due to insufficient free time I decided to choose something easier. Thanks to my friend we decided to take a proper die cast body and make a great resin out of it. And my friend offered a proper Monza body from unknown producer.
I only used body from die cast kit(including lights and reflectors). Undercarriage I took from Ford Sierra RS500, which dimensions fitted almost perfectly, but front and rear heights needed to change. Also I was able to use Sierras axles, which needed a lot of customizing. Undercarriage itself needed a lot of putty and plastic, since it was in a really bad shape when I got it. I added new rear fenders and frames to the undercarriage so new rims could fit. Front fenders needed widening. Model comes with full engine. I am probably going to replicate 3.0 12V straight 6 engine.
Since my graduation project includes practical part, I am going to start producing it. At the moment I am making a mold for the undercarriage. Soon I am going to do molds for body and other parts.
Some pictures (in chronological order)
Undercarriage when i got it:
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1183.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/Capture4.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/Capture3.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/Capture2.jpg
Undercarriage after neccessary changes:
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1214.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1216.jpg
Body with undercarriage and rims:
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1182.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1217.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1222.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1227.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1228.jpg
Making the mold of undercarriage:
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1229.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1233.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1234.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1237.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1238.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1240.jpg
Ready to make other half:
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1241.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1242.jpg

To be continued...

Eero

Then underside mold got ready so it was time for some test-casting. First cast was total failure. Epoxy concentration was wrong so the details were very fragile and broke very easily. So i rechecked the concentration and went for another go. I was quite pleased with the result. I got to know the amount of epoxy needed for casting. Now i need to make some arrangements in techniques and I am ready to continue casting.
Molds:
http://i157.photobucket.com/albums/t68/Eero16/Monza/IMG_2285.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/IMG_2286.jpg
Second test:
http://i157.photobucket.com/albums/t68/Eero16/Monza/IMG_2287.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/IMG_2290.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/IMG_2289.jpg
Then I Finished the mold of the body. I used wooden blocks to make the ejection of the mold easier and to save material.
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1270.jpg
Wooden block with supports.
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1271.jpg
Almost finished underside of mold.
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1272.jpg
Pouring upper side of mold.
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1275.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1276.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1279.jpg
In the end I cover it with glass and put powerdrill on top for weight.
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1280.jpg
Finished mold.
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1285.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1286.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1284.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1287.jpg

To be continued...

Eero

And also I am pouring and selling resin wheels and tires.
Here is a little list that I am offering right now.
1)BBS RS 17" (Fits Tamiya)
2)Nismo LM GT 4 19" (Fits Aoshima and Fujimi)
3)Alpina B7 15" (2 widths. Fits Tamiya)
4)American Torque Thrust 19" and 23"
5)Nismo LM GT 1 17" (Fits Aoshima and Fujimi)
6)OZ-Racing 18" (Fits Tamiya)
7)OZ-Racing-Turbo Ronal 18" (Fits Tamiya)
8)Advan RS 19" (Fits Aoshima and Fujimi)
9)Volk Racing RE-30 (Fits Aoshima and Fujimi)
10)Leon Hardiritt Bügel 20" (2 parts-dish is separate part)
11)BBS LM Cup 18" (2 widths) (Fits Tamiya)
12)Porsche Fuchs (Fits Aoshima and Fujimi)
13)Volk TE-37 17" (Fits Aoshima and Fujimi)

And there are more to come...

Here is a sample how they look:
http://i157.photobucket.com/albums/t68/Eero16/For_Sale/140412.jpg

Information by PM.

Eero

nice informative WIP. :)

What king of clay are you using? Nice tutorial, will help me with my 2 door golf i want to copy.

your castings look very clean, wheels look good!

Wow what kind of school program that lets you do fun stuff like this? I am envious.
Nice work so far! Keep it up! I am guessing the amount of silicone you are using is getting expensive too?

Wow what kind of school program that lets you do fun stuff like this? I am envious.
Nice work so far! Keep it up! I am guessing the amount of silicone you are using is getting expensive too?

The UNI of Technology. As I am a studing a product development then this is kinda a development of a new product. And creating a way of production.
Well, the silicone would get expensive, but I take it as an investment. I make molds of rims and other parts too and by selling them I can earn back the money to buy new amount of silicone. :rofl:

Thank you for the feedback!

Eero

Hello!

The first successful body is ready. It didnt came out perfect but right now that is not the purpose. Thanks to that I saw how the mold works and how I have to change my technique while pouring it. The body has some airholes, but nothing too serious. It should get better. :lol:
Here are some pictures:
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1316.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1327.jpg
http://i157.photobucket.com/albums/t68/Eero16/Monza/DSCF1329.jpg

Eero

Never saw one as a model - love it!! Keep it up!