Wood Molds

Some of the armor parts were easier to create using wood molds. I created mine out of MDF(Medium Density Fiberboard). In most cases I had to glue multiple pieces of wood together before I began to shape it. The wood sometimes came out a little fuzzy and some of the seams were showing in my pulled styrene. I used Bondo, and primer paint to eliminate this.

This is the beginning of the work I did on the lower back mold. I glued 8 sheets of MDF together. Each sheet was a little bit smaller as they reached the top. All that was left to do was dand down the sharp corners into a smooth surface.   This is the completed lower back armor. I wasn't totally satisfied with the way the seams showed up on the final plastic piece, so I eventually added some primer to smooth the whole piece out.
This is the Primed and Painted lower back mold   This is a picture of the abdomen mold halfway through priming
Another Picture of the Partially primed abdomen   Completed Abdomen Mold
Completed Butt Armor Mold   Left Kneeplate mold
Front portion of utility belt mold   3/4 Inch think piece of MDF. I made 9 of these, cut them out and glued them together to get a rough size for my chest mold. I was very happy with the way this piece came out. It took about 20 hours to complete.
Chest Mold after applying bondo and sanding.   Completed Chest Mold after Priming and Painting.
Upper Back is almost complete. There were a few dents that I had to patch with some Bondo. Sanding and Priming is next for this piece.   Bottom Side of the Forearm
Completed Top Side of the Forearm Mold   Completed Cod Piece Mold
Completed Knee Battery Pack Mold. This is my third try for this piece. This looks good and should form well.   Completed Back of the Utility belt mold. This one was really easy.
Completed Upper Back Mold    


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Jim Connolly
Charlotte, NC