The Booster Cover is a multi-angled unit and needed many more mathematical calculations than parts such as an outer foot.

Disguise the sub-construction with polystyrene sheets.

After the master model was finished I made the casting mould.

Building this casting mould lasted nearly as long as building the master model. I often used old "advertising polystyrene sheets" for casting moulds, as can be seen by the red writing.

After filling with silicon the casting mould had to be dismantled carefully.

This shows is all that remained of the painstakingly constructed casting mould.

The silicon mould, still on the master model and a supporting mould from GRP. Additionally I manufactured yet another supporting mould from plaster.


The finished cast part beside the silicon mould.