I want to form a male plug from an original female part but i dont want to use fibreglass!
Are there any other ways to form a good plug which I can then modify to arrive at the finished item? I was thinking about something like modelling wax which I think is reasonably hard at normal temperatures, but which could be warmed to become pliable and could tjerefore be pushed into my original female part and all the nooks and crannies, left to harden and then pulled out to give a good representation of the original part.
The reason I’m holding back from forming a more conventional fibreglass plug using the original part, is that there are a variety of details in the original part which I dont want to cut away from the original part in order to form a smooth plug. I would rather form a replica plug and then modify that.
I’ve looked at polyurethane foams, but it would appear that these will bond very well to the original part and there is a high chance I wont be able to remove the foam plug once set, without wrecking it in the process.
So I’m wondering if something like modelling wax or maybe even expanding foam are viable methods of getting a reasonable plug which I can then work on to form the final plug/mold.
Alternatively, expanding foam or polyurethane foam could be an option if there are any good ways of treating the original part first to ensure that the foam wont bond to the part.