Attempt to cast a hard body from a lexan the body shell

The original body Proline '85 Hilux lexan body. I was never 100% satisfied with it so it became destined for sacrifice...

Cast of the body shell in plaster. Literally just filled with plaster. Note that removing the cast destroyed the bed.

Set fenders into the plaster.

Grill template. Plaster was added here to increase the width at the front

 

Once the grill was cut a silicon mold was taken from the plaster. The mold should have been extended further past the edge of the body subsequently its difficult to cast. The silicon mold is supported by a two part fibreglass jacket

First cast in fibre glass with a coat of primer

A polyurethane slush cast (no glass fibre)

The bodies need a lot of finishing and don't have the definition of detail that you'd expect from a commercial hard body but at least I have a few to play with. They are also a bit heavy.