I have two parts that are basically flat aluminum sheet metal 1/8" thick that has been formed into different bends… about 3 bends per part. I was wondering if modeling clay built up thick enough could serve as a flange material for the plug. Would using that much modeling clay cause a problem and react with the tooling gel coat? We are talking about one square foot surface area of clay i’d be laying tooling gel coat over.
The other material i was thinking of possibly using is plaster of paris. Mix up a batch to cover about 1/2 deep into a soda can box ( you know the old 24pk case box). Then press the metal shaped plugs onto the surface of the wet plaster. As it cures wipe away the excess plaster that may have squeezed out onto the edges of the plug parts. What do you think… would it work? The plug would be destroyed upon demolding but that is ok with me.