1 Ok this is how i start. First shape in MDF the part on how i want it. You can see the layers of MDF i used and glued together.
2 Next i file it down so it with an even diameter. Note this is the final shape inside the cast. I paint it in epoxy so when l spray the wax it will remove from the mould easily
3 This is the part that will be the intake to the Rotrex. As such already sanded and awaiting epoxy coat
4 Then i make a box so the above part sits in it so as l can pour a 2 pac epoxy casting resin
5 This is with the part sitting in the box
6This is with the casting resin in and slowly going off. To the left you can see it going white as it sets
7 The same thing had to be done with the other half but in reverse.
The inter pipe is then removed , then the cast is taken out and sanded down to the final shape of the outside
8. These pieces will be taken to the foundary from which he will sand cast then and finally make the aluminium part.
Once its back ill show you the final photo.
Then its of to be CNC'd the ends . One side for silicon pipe and the other side for the restrictor and intake of the ROTREX