My first crack at building, molding and casting the Fusion Pistol from Bungie's Marathon 2: Durandal. Build time was about 50 hours. Trying to finish before my brother's birthday, I rushed the final stages of casting and did not get good results. It was highly educational, though!
I have yet to get more casting materials to try again, but this project is not dead!
Construted of MDF and Apoxie sculpt. Some adjustments were made to the grip area to make it wieldable.
Priming, sanding, etc.
Box mold - I learned I should have melted the clay and poured it in, or just not gone with this route at all. A brush-on mold might have been better for something of this size, even though I initially considered this project to be small.
The silicon mold didn't turn out great. I ran out of silicon and was unable to fully form the second half, resulting in a saggy mold wall (right).
Pouring the resin didn't go well either, compounding the inferior mold's issues. Trying to avoid smashing the thin walled mold, I did not clamp the box mold too tightly, which let some resin leak into the seam.
The wavy thin-walled mold is evident here, as well as a major air pocket (the chopped looking part in the trigger well). While I tried to tip the mold to fill that pocket, I should have just sprued another air vent from that point. The two-tone resin was just an experiment with dye, as I already knew the cast was not going well.
