advice needed on offsetting plug to account for material thickness

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#1

I have a job in to make some carbon kevlar skid covers for the part in the pic. I obviously need to offset the plug which can be the part itself in this case to account for the 1.5mm thickness of the moulding. Ideally I would make an aluminium compression matched set and press them out of prepreg but the qty does not warrant doing that.

Any ideas on offsetting the plug the correct thickness so I can take a mould?

I dont have access to scanning eqpt to manipulate the 3D data and cnc machine out of tooling block and have tried vacuum forming a 1.5mm sheet of plastic over the part but with poor results and lost definition. Sheet wax is a pain and I would rather not go there on a part like this if I can help it…

#2

tooling/molding clay? I was going to say sheet wax.

try other plastics if you lose definition. PE, PP, ionomer, topas, etc.

#3

I may well have to go down the sheet wax route cutting lots of little bits and then filling in the gaps and smoothing down.

Vacuum forming probably would have worked on a less comlicated part but I found that the plastic stretched and didnt give a uniform thickness and also the some of the sharp edges and holes didnt show very well.

#4

Vacuum forming plastic over the part seems like a good idea, but so is sheet wax.

What about that liquid rubber crap that is for coating handles of tools? Dip the part?