Foaming the arms and legs

So Easter holidays are over and I have access to the workshop again. I used Mould Foam 8 (R8) polyurethane expanding foam to fill the arm and leg moulds. The arms are actually surprisingly thin and only took about 400g each (with lots of excess). First pic shows how I will suspend the solid box section I milled down to fit inside some hollow box section (set aside for later), in the moulds so they'll be securely imbedded onto the arms after demoulding. Second pic shows part A ready to be poured into a bowl of part B - mixed quickly with a big disposable brush. Third pic shows the other arm mould after the foam has finished expanding and has totally cured.

The legs are a little bit more complex so I'll let the photos make sense of it - I temporarily taped the metal plate (that I made to sit embedded in the Kijimuna's bottom) onto the solid box section protruding from the inside of the torso's core (I put the torso back into it's mould for this whole process)). I then sealed the torso core from the leg/bottom cavity with several layers of polythene sheet - this is to stop the foam from expanding into the torso core (I want these parts to remain separate so they can be detachable for transportation purposes). I poured one leg at a time until there was only the bottom section not filed with foam. I then bolted the sealed off torso mould onto the legs and poured the rest of the foam through a hole at the bottom of the leg mould (I obviously cut away the flap of silicone that originally covered the fiberglass section I cut out).

You can see that the metal plate is now hiding inside the bottom and the torso will now locate perfectly onto the legs every time (hopefully!)