QUOTE (Backfire @ Jan 31 2008, 08:02 AM)

I gota learn how to do that. I make crude molds out of clay, and as such casts mostly made of clay. I have used sand to make metal casts, and also made metal casts from clay molds, very dangerous.
Attempted poly urathane once or twice but didn't get that right either.
I made molds from the wheeljack statue and created, piece by piece, my own Marlboor WJ statue. Not perfect but pretty good. Symbol for the stand and all. Some of my changes I actually like better, such as the launchers are from G1 molds, bigger and badder, the pose needs some work, but all in all I like it, and the original statue is FINE. I could probably use the molds to make other statues, started a Prowl but don't like the pose so I never finished it.
Himawari, how much do you think it would cost to make a mold of the PC buggy?
See there's the problem of getting snagged for making major repro's vs demand. I think anyone who wished to have a complete Diaclone or TF Magnus set would love to have one. I my self would love to have a couple, one in blue or white to go with the TF version, and if I had a Shining Magnis I'd like a clear yellow or solid yellow...but I don't so... Something like that, from a guy like me for $20 or so would be do-able. I can spend $50 or so no problem on a custom project, but like you say collectors can tend to be on the cheap-o side. Heck, pretty much just spent that on the red mirage KO.
I remember someone I spoke with years ago, I think one of the guys on the Diaclone.Net page was looking for an extra wheel for buggy.
I get a freaking work shop, I must learn more of real plastic mold making...
Well, let's see... material cost of just the resin for the amount needed for each completed buggy I'm going to estimate to be around $10-$15. I wish resin wasn't so expensive, but it is if you want decent material. Now, that is not factoring material costs for even making the mold, nor any labour time. I may need to spend anywhere around $60-80 just to have enough platinum cure silicone to have enough material for molds. This means that if my target price range was let's say $30/ unit, I'd already have to have at least 4 or 5 units to break even, and that is without even lifting a finger, nor covering other costs for materials like sulfur free clay, lego blocks or sintra and plexi used to make containers for the mold making, release agents etc.... Then, there is the cost of my time. Just to make the molds, creating parting lines, setting the part, creating runners and gates, preping the mold and silicone and degassing etc for every part of powered buggy I would estimate the job would take 3 hrs/part at least(shop time) and I would say it would be broken down to have around 8 parts/molds (off the top of my head) all two part molds. That would mean a whole day of shop time and at let's say $35/hr (what I charge when I do custom car emblems) that would mean $840. $840 Just in labour, and that is only to MAKE the mould, not casting the parts. Let's say I could cast a complete buggy kit/hour, that is $35 in labour per item. Just that alone is already $5 over the target amount. Why only one/ hour? I only considered the cost of making one mold, and I can only pour one mold at a time since the pot life is so quick. I have around 5min to usually work the material, and then there is cleaning and prep after or before each pour. So unless there is ALOT of demand for a paticular item without many parts, there isn't much use for taking on such a costly project unless if I were to consider my time $0.
Now, hobbiests do that all the time, and if I had some spare time, I may consider it, but only IF I know all my material costs would be taken care of and I could get /some/ return out of it.
As for REAL plastic mold making.... that is a whole new can of worms that I know already too much about since I went to school for 2 yrs on JUST that. First, you have your product design, K that one is easy since you want to make a copy and the hard part is already taken care of for you, BUT the $$$ needed to make a mold is were it becomes more difficult. Labour is always a killer. This is why alot of this works gets shopped out overseas or other countries where the cost of labour is much cheaper than if we were to get it done in house or local. Secondly, you would need to know what is required for machining the mold ie aluminum plug in a generic mould housing. Don't bother buying that $100,000 CNC machine, shop it out to someone who already has one, and the labour force and know how to do it for you. The same goes for the injection molding machine required. Do you know how to operate one? I do, but that doen't help you unless I'm doing it for you (which I'm not going to, so there

) I could go on about parameters of calculating the clamping pressure, shot size, and discussing time, temp, and back pressure, but I won't. Then, there is the material being used. How much do you know about plastics? Do you understand the Rheology of plastics? Probably not, nor do I think you want to. I really don't want to sound like a wet blanket, nor do I want to piss on your parade, but I see alot of people who have tried to go down this path, some actually do quite well (usually the ones that have money and are close to retirement) and some give up after knowing it is more than what they bargined for. Sure, I'd like to one day have my own CNC and small injection molding machine and make whatever the heck I want since I am more than capable of operating both as well as knowing about proper mold design, nominal wall thicknesses, radius constraints, draft angles, gate, runner, sprue placement etc... But after it is all said and done, if I really DID want to have something made, and I know I had the demand, I'd just ask a company in China or Mexico to do it for me. In fact that is what I would suggest to anyone who had a desire to have something made, the only problem is capital. You may get stuck with 10,000 items of your dream, and no return to show for it.
I'm beginning to rant now.... moral of the story, stick with casting.
Thanks. -Himawari