Molded Cases

[Spidy88]

I need help ASAP! I've been working on a completely custom case you can see in the Works in Progress .

My dilemna is I can't find a material that is somewhat cheap to make my shell out of. I'm using Plaster of Paris which on the label assured a very solid finish but upon further inspection and a artistic mom found it to be flakey and demolishable on any decent sized drop.

So please if someone has a website or store or idea or ANYTHING that can help me finish my project, I'd be much obliged. This is the 2nd to last and hardest step in my entire project and its KILLING ME.

Extra Details:
I'm making a computer with a cookie monster shell that holds the main frame of the computer. See link for pictures. Right now I'm trying to make the shell out of Plaster of Paris but need something more durable and not cheap but not horrendously expensive.

Is Plasti-Paste the best option for my type of case?

[halcyonforever]

Bondo is a group favorite... Not horibly expensive but incredibly strong and solid once in place.

[Bopher]

Fiberglass, if you know how or want to learn, how to use it and a well vented area to work in.

[Mach]

As mentioned fiberglass is your strongest bet but the learning curve can be steep. Check out the following for an extreme example:

http://www.thebestcasescenario.com/forum/showthread.php?t=9665

For the master of bondo, check out Defyant's HP3 mod

http://www.thebestcasescenario.com/forum/showthread.php?t=550

Can you explain a little more in your worklog how your using plaster? Are you going to cover the plaster in fake fur? The correct type of plaster can be extremely strong (Hydrocal or Ultracal, IIRC). It sounds as though it was contaminated or mixed improperly.

Plaster would need to be fairly thick to be strong enough on its own. What are you using for support underneath to hold the shape? Chickenwire, wire screen? Plaster bandages are easy with the proper support underneath and papermache can work also, especially if your using fake fur. For the goby fish, I use a styrofoam ball as the main support (similar to your pot) and wire mesh to build out the features with plastiroc on top (which is premade papermache). I used plastiroc because I needed the texture but if I was covering it and weight wasn't a concern, plaster would have been an option.

http://www.thebestcasescenario.com/forum/showthread.php?t=622

With wire mesh underneath, paper mache can be lightweight and strong.

http://en.wikipedia.org/wiki/Papier-m%C3%A2ch%C3%A9

http://www.austinmodders.com/modules.php?name=Forums&file=viewtopic&t=1636

On your Plasti-Paste question, I've never used it but it seems similar to fiberglass but not as nasty from an odor standpoint. It is recommended for mother molds or support shells. Not sure this is what you're after though.

http://www.smooth-on.com/plugin14.htm

[Spidy88]

ok thanks. i actually have no support for outer shell. I was hoping for it to be standalone with the main frame mounted inside. Paper mache was my first thought when starting this project but I didn't think it'd be strong enough. guess I was wrong. I'll have to look into fiberglass, although I'm not sure it'll be able to bend like i need it to. Thanks for the help, I can continue finishing my project now.

[Mach]

Fiberglass is alot like paper mache if done over a form only much, much stronger. More advanced projects will make the master out of clay or plaster, create a mold out of the original, and then cast in fiberglass a duplicate. A more involved process but more professional. This is what the modder in the first link is doing.

Another method is to apply a skim coat of plaster, bondo, papermache, or bondo over a form. Based on your comments, I'm guessing that you are doing this. Take a look at LostBoyNZ's Chobits projects, http://www.thebestcasescenario.com/forum/showthread.php?t=6379. He's building a mounting frame with a foam surround that'll be covered in a skim coat for finishing. He's using Miss Kana as inspiration http://www.mini-itx.com/projects/ern005pc/. Katsuya used micro-hollow-globular-resin-clay for his skim coat. Which looks like an air dry clay, either epoxy like milliput or water based like paper clay.


Here's another case mod for inspiration. The leela PC:

http://vang1.net/index.php?page=leela

Looks like he's using some kind of caulk for a skim coat. Anyone who reads finnish know what Acryylimassa is?

Hope it helps.

[Spidy88]

i've seen both of those mods before and i think they're great. unfortunately i'm so far into this project already I don't want to spend any more money finishing it. so my final decision is adding the plexiglass sidings to the case and then building a stuffed fabric cookie monster over the top. WAY cheap, kinda cuddly (since its for my g/f) and a TON easier. next time i mod a case though, definitey using the paper mache and fiberglass method

[Mach]

Yeah, sometimes easy wins hands down especially when you're on a deadline. Good luck with it and post pics to the worklog when you get a chance.

[Acey]

Paper xD

[Eclecticos]

So please if someone has a website or store or idea or ANYTHING that can help me finish my project, I'd be much obliged. This is the 2nd to last and hardest step in my entire project and its KILLING ME.


You may want to check out what they have over at SmoothOn.com (http://www.smoothon.com/)
They have many different compounds that can be used for moldmaking and casting.

Here (http://www.hirstarts.com/moldmake/moldmaking.html) is some additional information on moldmaking.

[ChevronX]

Thanks Eclecticos

Info is helping me in my case as well.

Good luck with yours Spidy88

[Zeus]

have you considered making a rudimentary structure using baling wire? Then you can build on that. It should give you enough stability to make it still "stand alone" or at least make it look that way.

Just a thought.

[Spidy88]

I didn't consider any of that until after my first failed attempt. so all these ideas will go into my next case as this one is not for me and not worth the extra money