Now with both the back and the logo finished, its time to stick them together. I find super glue is by far the best for this sort of thing, as it sticks nice and quickly, but has no mass to it, unlike epoxy two pack, which I find either ooze out round the edges and need cleaning up, or when you press on it, it slides around. Neither is very useful, so superglue does just fine.
With the badge finished, its time to make a mould of it. To start with I made a silicon mould, but the metal heavy resin didnít set properly against it, so the surface never polished up as I wanted. To cure this I made a simple mould by heating up a piece of plastic sheet, and forming it over the prototype base. By suing plastic the resin set properly against it, and polishes up just fine.
So with the base sorted out I turned my attention to the Psi Corps logo. In the first attempt the logo was cast in resin in with the main badge, but as mentioned it never polished up as well I would have liked. So now I have ventured in to pewter casting, I decided to make the logo out of pewter so it would be shiny.
A mould was made, and unlike resin it needs to be a sealed mould of the pewter just pools in the middle. One half was made, then the Psi logo left in place and the second half cast. When set, a fill hole was added and a few air escape holes.
Once cool enough to handle, which only takes a few minutes once solid the pewter cast is removed form the mould and placed to cool. A small amount of clean up work is required, and a bit of polishing, and its ready to stick on the main badge.
I kept the old silicon mould so the pewter logo could be placed in the old mould, and epoxy glue applied to the back, then the badge back is placed on top in the mould this way the logo is glued in the right place. I then place a bit of hardboard against the back of the silicon mould, and using a clamp make sure the badge and logo are pressed firmly together.
The finished item comes out much better than the first all resin attempt. The main badge is much shiner, and the logo looks muck nicer as well.
At the time I hadnít ventured into pewter casting, but the advantages of casting small bits in metal instead of resin means I can make things previously unthought-of as they would have been to weak in resin.