Steve, I bookmarked your page. It will come in handy in the future.
Casting. For the best explanation visit the thread in the projects forum (I'll post a link)
Here is the short version. I create a master peice from styrene, glue and any other parts that I can come up with. (the heads are from styrene superglue and aluminum tubing) Then a High Stregth RTV silicone is used to make a mold of the original part. Once that has cured, I use a 2 part casting resin to cast the part.
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