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Author Messages Oldest First Newest First MDKline Posts:1 04/19/2009 9:19 PM Alert  I was hoping someone with a sculpture or other related background may be able to give some input on casting with polyester resins. I'm trying to replace one lens on a light bar. www.lightbars.net/code3xl.htm shows what I need to recreate. Under the center metal part (speaker cover) is an empty space and the clear end cap on the blue lens is removable. Both sides are identical, so I should be able to use the good lens to make the mold. To do this I hope to make a two part, plaster or concrete mold (RTV is too costly) and use a clear polyester resin with UV resistant additives/transparent orange dye (need amber by law). The lens would be about a 1/4 inch thick. The end cap will be cast as a separate piece. Will this work? Can I cast the resin in the plaster/concrete? What type of release agent should I use? Will the end product shatter easily or provide some impact resistance? I rather not spend the $175-250 to buy a new lens. I hoped casting would be a cheaper alternative, along as provide me the opportunity to learn something new. I have a DIY vacuum former, but the lens is too large for it/my oven. If this will not work, are there other suggestions? marilee Posts:4 05/12/2009 7:41 PM Alert  Hi MDKline,   It looks as if the lens covers a light.  Is this correct?  Concrete would be very heavy and I don't know how resin would stand up covering a light as it has a plastic base.  You might want to look at sheet metal which comes in varying thicknesses and can be bent into shape.  You can rivet it together with a rim or however it needed to fit in the bar. I use all these materials in my sculpture. I hope this helps you some. Marilee
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Forums > Gallery/Topic by Medium > Sculpture & 3-D > Casting Help

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