Hi I have the manufacturers name moulded into my campervan's pop-top fibreglass roof but I would like to replace it with the campervan's name PHILEAS.



I will just sand it off so will have to make it slightly bigger to cover the sanding I have purchased chrome letters that you put on the boot of cars, in order to make a mold from but have no idea how to do it or products to use. HELP!!



Here are my letters I bought





The original is on a type of plinth aswell any pointers gratefully received.

Hi,

Interesting little project, seems like an ideal candidate for a silicone mould and casting resin.

First job would be to cut a piece of material (Plastic MDF metal... anything with a smooth surface) to the size and shape of the base plate, then glue your new lettering onto this to create a pattern.

You will then need to mount the patten into a water tight box that is a little bigger than the part, this box has to contain the silicone when it's poured waxed MDF or wood is fine for this as long as to joints are sealed.

You are now ready to make the mould, simply mix a batch of silicone that will fill the box, covering the pattern. carefully pour this over the pattern and leave to cure.

After curing the silicone can be removed from the box and pattern, this should remove really easily even though no release agent has been used.

Making the part from this would be a really quick process, just mix up a small batch of fast cast resin and pour it into the silicone mould (again no release agent required) this will be ready to release within an hour!

To finish the part up you would just need to sand the back of the plinth flat with a sanding block (as this was the open end of the mould and will have the od ripple), to fit it I would spray paint it to colour match, then simply grind down the original one and bond this in place.

Everything you would need to cast this part comes in a handy kit found here There are no seriously harmful chemicals or smells involved so it's something you could probably get away with doing on the kitchen table!

Paul Statham
Easy Composites / Carbon Mods - Technical

I did look at the silicone mould and casting resin, so i'm glad I was on the right track.

I take it the part will come out opaque, as you say I'll need to paint it, is there a white pigment I could mix in with the resin, or is this not recommended.

Thanks for the "how to" I'm feeling very confident now.

Yes, you can add pigment of any colour to our FastCast PU casting resin. Make sure you choose pigments designed for polyurethane (i.e. don't use pigments designed for polyester resin or for epoxy resin). We have a limited range at the moment (please call us) but we'll soon have a full range of pigments for PU, EP and PE.

Matt Statham
Easy Composites / Carbon Mods - Technical Sales