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This has been bouncing into my head for a week or so. Try using plastic auto body filler (Bondo is the big brand name), check auto body supply shop, much cheeper than auto parts retailer. For the casting of the pattern, try the "duraglass" type filler, much tougher. I would seat the firearm in a plastic bag of some kind, vacume seal or something like that. The last time I purched any type of auto body plastic it was about $20.00 a gallon. I've heard of people making molds and patterns this way for limited production on the cheep. I found this after a two minute google search http://hacknmod.com/hack/the-power-of-bondo-a-comprehensive-tutorial/

Please let us know about progress.

Edited by MBOGO
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