Closed shell adventure - new tool: rotocaster

My major sticking point has been making custom shaped inflation bladders.

I don't mean airplane fuselages - if that is the letter "I", I am trying for shapes like "K" and "J" and eventually even shapes that get out of a single plane, as in, where fused seam lay-flat bladders simply won't work (apart from the fact that I keep bursting them... I've tried, a lot).

I learned a few months ago about rotocasting. It is used to make large, hollow parts of little material value using as little material as possible. Mannequins and plastic lawn ornament alligators are easy examples.

After some good guidance, including from compositepro (thanks dude), I decided to build my own rotocasting machine. Why?

...Have you priced a rotocasting machine lately? HOLY CRAP. No thanks.

Further, getting a small run of bladders from a composite specialist company is very expensive. They operate in bulk, it's too expensive to justify as a small fry. Don't believe me? Do your own homework, I am sure you will find the same. If not please send me a message, LOL

I made this one for... I'd guess $300 to $400, I'm not exactly sure. I made several mistakes in hardware which cost me extra. One thing I was having trouble with was finding a suitable motor for cheap. Finally landed one recently at a misc surplus store, found a bin of high quality motors for $9 a pop (original price > $100). I am now a surplus store junkie...

I don't have any results yet, I'm running the first resin test right now! Here are some videos of the machine in action:

Internal view:

(This one may affect people who get motion sickness easily)

http://www.youtube.com/watch?v=qcsweEzvfHw

External view:

http://www.youtube.com/watch?v=WdHNn7jhz9A