It sure is doing things the hard way, but if i can figure this all out it will be worth it in the end.

I tried to make an acrylic part to make a mould from, I think I need to start with a slightly larger sheet and it will work.

The top left corner let go and the sheet went all wavy.

That uses up what I had lying around, so I will have to buy some now. at least I did my learning with scrap. I'll see if the sign writers near work can help me with some offcuts.

Top work man, theres gonna be alot of orders for these once you work out how to do it!

I haven't looked into your thread but is there any reason you wouldn't make this part out of metal, fibreglass, etc? Fibreglass is quite good to work with once you've had some practice.

Ok well it got the better of me so I went looking at your links above.

This may be a long-shot, but there's a sprayable product you can get that is designed to replace electrical tape. I think it's for use in hard-to-reach places. Some electronics stores should sell it, or be able to get it. It think it's called liquid electrical tape?

Anyway this stuff is supposed to be used for spraying on wire to insulate it, and cures by air (I assume it has a thinner in it that evaporates). It's about $25 a can so not cheap, but if it solves your problem then it will be money well spent. You would obviously need to spray it over something, so some thing like very thin alloy sheet formed to shape.

If you are doing that though, you could also just make it from alloy and powdercoat it for a professional finish.

Thank you shifty, I will consider it if what I am trying fails, but I am pretty far down this road now...

I am about to place my order for some elastomer tomorrow, I have been sending alot of emails and making alot of calls trying to find what product best suits me,

The idea so far is to use the Eratwowel MT80A mixed with some black pigment, for one side, and to use some high temp silicone mixed with black pigment on the exaust side, pack it with some fibreglass to stop heat transfer and back it with Eratrowel MT80A to keep it from deforming, as the Eratwowel has a much higher duro than the silicone.

I want to use high temp silicone on the exaust side as the Eratrowel is only good for around 90deg c.

I went to a company near work that makes bags from silicone and uses a weave in the centre for strength before work today.
From what I saw this morning silicone will do the job and look right.
I just have to see if the pigment I am ordering for the Eratrowel will work with the high temp silicone the guys near work are using.

let me know if you need help with getting pigment i can get the stuff for free (if you haven't already)

Pm sent, Thanks leith.

I got my rubber today,
It looks like this is going to be more of a long term project.
Here is where I am at so far..

Rubber suspension cover 3

Hi mate
Im a conveyor belt splicer and use uncured rubber most days of the week.If you go to any of the splicing companies and offer up a carton someone help you out with some offcuts.I would myself but in WA.When you heat up the rubber it has to have pressure on it otherwise it bubbles up like an aero bar.For example we do repairs to belts with a small vulcaniser and it needs 60PSI
Hope this might help.
Sean

Cheers, I have kina of ruled out uncured rubber for now becuase of the need to vulcanise it.
Im not sure what heat will do to the wooden block on my jig.
Just the heat gun through a rubber sheet cracked the car filler when the wood heated up.
I need to use my block for a left and right because I flip the top plate and bars to swap between sides.
I have a mate that gets urethanes poured regularly, I may have a chat with him when I get my moulds finished.


Where I am at now...
The release agent for the urethane I bought is what concerns me, it says a structural firefighters uniform is NOT effective for this material,
It requires a SCBA and fully encapsulated gas tight suit.
It is hazchem 3[Y]E.
IM better off getting a profesional to use it, as I don't want to spend big money on a suit.
Just the mask is nearly 2 grand.

Thank you for the info, I do appreciate you going to the effort by replying to this thresd for me.
Cheers, Ashley.