RE: Byron 51 Build Thread
<p class="MsoNormal" style="margin: 0in 0in 10pt"><span style="line-height: 115%; font-family: ">I have been in a small holding pattern on my build because I was missing some plastic parts. The wind hold down saddles. I needed two front and two rear but only have one of each. I have been looking all over the net but this isn’t producing any results so I decided to make my own.</span></p>
<span style="line-height: 115%; font-family: ">I located an amazing product called Insta-Mold at a craft shop (Michaels Crafts) and have learned how to reproduce any part I need. I can make parts out of epoxy, plastic, J&B Weld, or whatever I want as long as the curing process temperature doesn’t exceed 300 degrees.</span></p>
<span style="line-height: 115%; font-family: ">Picture 1
I used a plastic paint brush/paint holder (container) to make my first mold. You can find these at any hardware store for pennies. </span></p>
<span style="line-height: 115%; font-family: ">Picture 2
Plastic part I want to replicate</span></p>
<span style="line-height: 115%; font-family: ">Picture 3
I mixed the Insta-mold with water (50/50) and poured the first half of my mold into the container. While the mold material is still liquid I inserted the plastic part I want to replicate. It is also important to insert at least two additional holes into the mold as alignment guides.</span><span style="line-height: 115%; font-family: ">Once the mold is poured it only takes about 10 minutes to cure. Now you can mix up another batch and pour on top to create the top section of the mold. It is important to note that Insta-mold doesn’t stick to anything including itself.</span></p>
<span style="line-height: 115%; font-family: ">Picture 4
New mold removed from container. I took a long thin flathead screw driver and ran it around the edges of the mold while in poped out with no problems.</span></p>
<span style="line-height: 115%; font-family: ">Picture 5
Mold separated and ready to pour with the plastic piece I want to replicate removed. I mixed up some 5 minute epoxy and filled the center hole of the bottom mold. I placed the top of the mold back in position and the excess epoxy leaked down the sides of the mold. </span></p>
<span style="line-height: 115%; font-family: ">Picture 6
This is the new wing saddle created beside the original</span></p>
<span style="line-height: 115%; font-family: ">Picture 7
Insta-Mold Packaging.</span></p>
<span style="line-height: 115%; font-family: ">You can add any dye or food coloring to your epoxy to make the part in any color you want. You can also purchase liquid plastic resin and catalyst if you want to make plastic parts. I even made one out of JB Weld.</span></p>