In previous threads, I've mentioned that I'm planning on putting a 8.4" 4:3 LCD panel in my 2003 WRX's dash, behind the radio bezel.
The LCD is just the right width for the opening, but it's about 2cm too tall, so I'd normally have to modify the bezel.
Instead, I'm going to make a copy of the bezel using casting techniques and silicone rubber with polyurethane plastic, and will then modify the copy to fit the LCD.
In this thread, I'm going to detail how you go about casting a duplicate part, using a 2-part mold.
I've attached a few images to this post, and I'll go over them now.
This image shows how the LCD panel would stick out behind the bezel, and is shown for reference.
In order to cast this part using two halves of one mold, I'm going to have to make a copy of one side, then the other.
I'm going to start with the front side, since that's the more important side to me.
In order to mold the front side, I'm need to fill in the holes so the rubber doesn't pour through.
In this picture, I've cut out pieces of sticky-back foamboard to apply to the back of the bezel to cover the holes. The top piece is actually two pieces stuck together, and actually fits inside the opening, reducing the depth of the opening by 5mm.
Applied to the back:
Viewed from the front:
There are some minor gaps in between the plastic and the foamboard, and they will be filled in with some modeling putty.
The next few posts in this thread will show the making of the box to hold the part, and the mixing and pouring of the rubber (tomorrow).