After making the foam plug and covering it in bondo i cut up some manila folders and marked lines on the mold so i could see if i had it at least near to the shape i wanted. One change i would make when doing this is make the foam smaller than the finish shape. When i would fair the bondo down i would start sanding thru and hit foam and this turned into a big issue trying to get the correct shape. Also i made my finish product slightly larger than what it should be so i have room to work with the lead bulb and get that to the exact shape i want. Its better to be to heavy than to be to lite.
This is the place i found the sections for the plug shape. About half way down the page.
http://www.i550.org/index.php?option=com_kunena&Itemid=2&func=view&catid=7&id=502
Finiished plug after 30 hours of fairing.
This is the Concrete i used. I chose mortar because it has no stones in it and its pretty smooth. I am concerned with the streingth. Time will tell.
Plug in the box we build for the mold. nothing fancy here just a box built out of 2x4's and plywood.
My buddy Matt spreading out the motar
Here is the first half of the mold poured. I added the two light bulbs in the mold to make alignment holes. Now when i pour the top half it will make the negative of the hole from the bulb then when i put the two halves back togeather they should align nicely. I still need to put a thin layer of plastic down after this hardens and pour the top half with a pour hole and two vent holes. That will hopefully be done later this week.
A few more pics.
Hour Count- 5
Total Hours so far-80
Beer - 5
Total Beer - 21
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