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In lugnet.build.minifigs, Norbert Black wrote:
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A primer on making custom elements for use with Lego(tm) pieces.
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Brilliant!
What a fantastic write up and what a nice glimpse of your true skill.
Originating entirely new sculpted parts and then working them to a “Lego like”
finish is great. And important as far as I’m concerned. If people really need to
have a good knowledge of what Lego elements are or were actually available to be
able to detect your work, then you’ve done it well :)
I make a few parts, but they aren’t even in the same league. I avoid having to
restore the surface condition by cutting pieces from normal parts which can then
be glued together into a new shape.
I love your idea of making reinforced internal structure. Curiously enough, that
substance has an official name - Paxolin, which is an SRBP or synthetic resin
bonded paper. I have also discovered that “super glue” will soak into paper and
make a tough but thin structural element. ABS is slightly soluble in superglue
and although it slows the curing process, can attach quite strongly. (I have had
problems getting epoxy to bond well with ABS.) You can get gel super glue which
will retain its bulk after it cures, and can then be machined. I’ve used this
occasionally, although with most of my work which just involves re-attaching
pieces of ABS to each other, I use MEK with filler. And to repeat your caution,
a lot of these materials are bad for you. Keep dust out of your lungs especially
epoxy and fiber glass, and keep solvent fumes under control. A fan or an
extraction system are important but necessary accessories to a work area.
JB
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