Project Monza-from die-cast to resin.

[Eero15]

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:




Undercarriage after neccessary changes:


Body with undercarriage and rims:





Making the mold of undercarriage:






Ready to make other half:



To be continued...

Eero

[Eero15]

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:


Second test:



Then I Finished the mold of the body. I used wooden blocks to make the ejection of the mold easier and to save material.

Wooden block with supports.

Almost finished underside of mold.

Pouring upper side of mold.



In the end I cover it with glass and put powerdrill on top for weight.

Finished mold.





To be continued...

Eero

[Eero15]

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:


Information by PM.

Eero

[nugundam93]

nice informative WIP.

[MidMazar]

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

[euro_z]

your castings look very clean, wheels look good!

[kaho]

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?

[Eero15]

Originally Posted by kaho

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.

Thank you for the feedback!

Eero

[Eero15]

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.
Here are some pictures:




Eero

[Brat_R]

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