-- Originally Posted August 30, 2008 --

After the last success with contour-fitting, I realized the same could be done for the large keel extension - which would at the same time eliminate any need, during installation, to cut into the hull.

So again, some more Reverse-Molding resin casting:


Click on Image to EnlargeTo absolutely ensure sufficient coverage, I targeted the entire area from the main deck (crease, or "knuckle" in the hull) level down to the keel (top); starting with the port side. Note the MoldBuilder® latex, dried almost clear, blots out fine textures but does leave all significant contours well defined.

Rotating until the trough of the box is at the bottom, the resin fill creates a long, triangular block perfectly contoured to the port bow (bottom; looking like a some sort of special effect from the original Star Trek TV show!) Again, the type- and total volume of curing resin must be considered to ensure it will not create so much heat as to warp/damage the plastic.

When hardened sufficiently, the resin let go of the surrounding plastic dams - but the resin block itself was left (well-stuck) in place on the hull:


Click on Image to EnlargeThis provided a nice foundation on which to mount the plastic walls (left) for the starboard-side application. At right, the poured resin is still very fluid; the angle (in 3 dimensions) at which to position the hull is not at all predictable ahead of time - at least, not with any precision - so the whole process becomes quite empirical/intuitive, once the pouring begins.

The result was a couple really nice, oversized form-fitting blocks (don't know why I didn't snap pics of them); easily providing the coverage and bulk required for the forward keel extension.

I realized that contouring of the clipper bow and top flare pieces could also be extensively improved - for easier and more secure for construction - as well. But before I show you that work, tell me what does this remind you of:


Click on Image to EnlargeThe "royal" purple, the golden "head dress" - right down to the lined "lion mane" pieces - I swear I must have wanted subconsciously to sculpt a bust of an Egyptian King or something! (Must just be to damn hot around here these days...)

But of course, what it really represents is the containment for more reverse molding:


Click on Image to EnlargeMainly the clipper bow, but also the base of the flaring upper piece; giving them both more extensive and secure attachments (left), particularly the former (right).

Up and behind the top piece, resin was also poured into the cutout for the emergency con portholes in the very tip of the Revell bow:


Click on Image to EnlargeWith the result, after hardening and a little cleanup, that these prostheses virtually snap into place, sure and secure.

The prospects for these upgrades are looking increasingly exciting. And again, soon these "uinversal" master templates will be copied for customization into the three distinct types of Essex hurricane bow enclosures.

Cheers,

-Matty