I tried making a mold out of wood. It is not working out so great. Bits splintering off and a deficiency in woodworking tools makes it difficuklt, even for my simple design.
Any alternative ideas for someone with an average amount of tools? (I got saws, metal saws, hammers, screwdrivers, chisels, etc., but nothing fancy like a CNC machine)
Plaster? would it shatter? Any ideas tht aren't crazy? (I'm vaccum molding so something like styrofoam or plaster is out of the question)
Mold ideas?
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Kurt_
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Mold ideas?
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bicostp
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Sculpey is pretty neat. It's a craft clay which hardens when you bake it in the oven. You could make the general shape out of wood, then fill in the curves and details with Sculpey, then bake it and sand the clay smooth.
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I've asked this before and never got an answer, and it's relevant to this. Would a mold made out of parrafin wax hold up under the heat of the melted plastic? I'm thinking that if you coat it in talcum powder it may keep it from sticking, providing that the wax doesn't melt. This would be good because wax is easy to sculpt. I'm not exactly sure how hot the plastic gets in a vacuum table, and I can't use that as a bearings for how much the mold must be able to take.
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bicostp
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I don't think wax would hold up well. If you have to heat the box up enough to soften the plastic, you will probably wind up turning your mold into a puddle.
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plaster 
i know ive posted a really small way of making a plaster cast in someones thread but here is the gist of it
make a clay mold of what you want your case to look like (several inches thick no matter what the desired thickness is)
cover that clay mold in a plaster cast pretty thick maybe 1/2 an inch
once it dries take the clay out, grease up the cast with whatever (vaseline worked best for me)
then fill the cast with plaster
after that dries (let it dry overnight make sure that it is dry)
then snap off the edges of the cast with your hands to try and get the cast off of what should be a plaster form of your original clay mold
i know ive posted a really small way of making a plaster cast in someones thread but here is the gist of itmake a clay mold of what you want your case to look like (several inches thick no matter what the desired thickness is)
cover that clay mold in a plaster cast pretty thick maybe 1/2 an inch
once it dries take the clay out, grease up the cast with whatever (vaseline worked best for me)
then fill the cast with plaster
after that dries (let it dry overnight make sure that it is dry)
then snap off the edges of the cast with your hands to try and get the cast off of what should be a plaster form of your original clay mold
