Overkill for what you need but it may give you some ideas. It was constructed with a wireframe, covered in wire mesh, paper strips, Scultamold and then resin. Have a look at my Terminator build that details some of the methods you could use. Fairly cheap, and quite strong if reinforced with strips of paste soaked newspaper or wire mesh. I've used a product called Sculptamold in the past (ready made papier mache) that you mix with water and it can be pressed into latex moulds, or shaped like normal clay. I still wouldn't use plaster as many have said how heavy it would be, and it would still be brittle although less so than unreinforced plaster. If you're determined to use plaster you can strengthen it with plaster bandages, cheesecloth, burlap, chicken wire, old bedsheets etc. Good luck with whatever you choose to do. If you use this method, congratulations, you will be the owner of the heaviest bio in the world. Total cost on that method should run you about $8. Dip your cheesecloth strips into the plaster mix so they're nice and soaked, and then lay them in the mold. It should have a nice thick consistency, still fairly runny though and definitely not lumpy. Cut it into strips, and mix up some plaster. Your local hardware store should have it. If you're set on using plaster of paris, you need to buy some cheesecloth. Of course, the brittleness can be solved by using a lot more material, but then it will weigh a ton more. This is how most of the Halo costumers finish up their pepakura armor. It will be heavier and somewhat more brittle than using fiberglass or regular casting resin, but it'll work, and all for an outlay of about $24. Slush it round in there until it sets, try and get an even coating everywhere. Mix them together in a 50/50 ratio or something similar (you don't need to be exact, it just needs to be a thick but still runny consistency, and don't forget the hardener!) and then pour it into your mold. Then buy yourself some of the bondo fiberglass resin as well. Buy yourself a tub of regular bondo, the standard kind is fine. Second, while it is possible to strengthen plaster of paris, I don't understand why you need to use it. if you mean casting the bio in hot glue.why? It'll flop around like a boned fish. I know there's a huntorial around here on it somewhere, you should search it out. If you must have the least expensive material available, the caulking silicone you can buy from home depot or lowes is a better option. OK, couple of things.are you talking about making a mold out of hot glue? That's not a great idea if so.
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