Looking to make a 15mm spacer for an airbox, there is a very complex pattern on the bottom for the throttle bodies, so was thinking of making an impression in clay of what is required then casting it in plastic or hard rubber. Any ideas on what material I could use?

Would fiberglass resin (polyelster or epoxy I guess) work? It'd be a bit brittle if just resin but you can get reinforcing material to help bind it together, kind of like the usual fiberglass matting but looks like its been blended into a fluffy powder like >Linky< ?

have found a tin of this in the garage

http://www.devcon.com/products/products.cfm?brand=Devcon&family=Flexane%C2%AE%2094%20Liquid

recon this could be absolutely ideal!

Lol, how comes I can never find anything so obscure yet massively useful in my garage!!?

Wax?

quote:

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Originally posted by rusty nuts
Wax?

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try polyurethane resin at http://www.tiranti.co.uk/

Used wax as a pattern to make a mold in sand years ago at school , wax was then melted out leaving a mould into which we poured moulton aluminiun . Just a few casting marks to cleaN OFF AND JOB DONE.