I successfully cast the chest plates this fall (see Shell Casting Success), but after many casting attempts on hip bones this winter, I finally ran out of slurry. I can't order more because it would arrive frozen, resulting in permanent chemical damage.

Issues included areas that cooled too fast, porous surface, and pieces of the mold breaking off prematurely:

So, I am switching back to box casting. Here's the breakdown of the parts I have left to cast:

Shell casting with SuspendaSlurry

• Hip Left
• Hip Right
• Chest Base
• Shin Snockplate Left
• Shin Shockplate Right

Box casting with UltraVest

• Hip Bottom Connector
• Spine Top
• Spine Bottom
• Spine Middle Left
• Spine Middle Right
• Foot Upper Shock Plate (2)
• Foot Shock Plate (2)

I also started working on polished sheet metal bracelets to attach arm bones without using elastic belts or gauze (like in the movie).

The prototyping session:

The parts I uploaded to RSM RapidQuote: