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Yard Master & Research
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Discussion Starter #1 (Edited)
Today I am just working on a gondola with a broken section.

I start off with a mold on the good side. Construction paper and blue tape.



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When ready pour the plaster.

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A few hours later. I chipped the edges to free the shell up.

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Neat, do you use plaster of Paris for this, or a secret recipe? Last time I was at Hobby Lobby I saw a resin casting kit but it was around $70 but they have 40% off coupons all the time.
 

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So the plaster makes the mold? If so, do you use release agent or a bond breaker? Also what are you casting the parts with?

Thanks,
Chris
 

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Yard Master & Research
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Discussion Starter #7
Construction paper and tape make a box around the object.

Plaster is mixed with water and poured. Dry time about three hours I may add heat with a heat gun to warm it up.

Intricate surfaces are difficult because of breakage. On the mold I do paint it with craft paint and that helps the epoxy separate.

This is the good side to the gondola. I molded this then I flipped it over to the bad side and added epoxy to the hole.



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When I started I bought a small package at Lowes or Home Depot and practiced on box cars, caboose and gondolas.
 

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Yard Master & Research
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Discussion Starter #9
I came across many broken roofs using this method the cars were improved. The only other method is to cut a piece out of a scrap shell and epoxy it to the new.
 

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Yard Master & Research
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Discussion Starter #11
Mold and epoxy

The molds were old and reused.


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This corner was a little thin after sanding and I had to add support it from the bottom.

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Not too pretty but too early to judge.

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This underside is heavy too.

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Yard Master & Research
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10,444 Posts
Discussion Starter #13
A little detour, frame and trucks.

Some wire action was needed. Primed and painted. The lamp socket was cleaned with a small Dremel brush.

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Very little rust here a quick clean and new wire.

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Railroad Tycoon
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What did you do, hand paint it?
Looks good, Did Top hat approve? :)

So I lost count what is the #30 caboose now? :p
 

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Yard Master & Research
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Discussion Starter #16
It is brush painted. I could of added a little shine but it is close.

The other caboose is the same number but more red in color.

It is hard to resist a caboose with a light and battery box.
 

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Moderator
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Very nice junk box casting repair work, T. Most people would just toss these old relics. So nice to see them given careful t.l.c. in your hands!

TJ
 

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Yard Master & Research
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Discussion Starter #18 (Edited)
Just trying to figure out attachments,
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The tower of dots have the edit button. For a moment I thought I would have to delete and rewrite the post if I could not edit. Also this is a full size picture. The rest of the post shows thumbnails that you can enlarge to see.
 

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Yard Master & Research
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Discussion Starter #20
You are right Ed, full size is better. The dark mode is better. I am still getting confused with the screen. There just is not enough boarders. I view a thread then I jump to more threads?
 
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