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Might as well post and update-
Problem: As you can see in the last picture, the corner by the big tab is missing. This is because of the mold and the pouring point. This creates an air pocket and doesnt allow the resin to flow into that area.
Solution: I drilled a small hole through the mold to create a air pocket, this should allow the air to escape and the resin to flow in.
Problem: As seen in the last picture is one of the thin wall tabs towards the top of the handle. Indeed another air pocket.
Solution: Shake/have mold angled when initially pouring resin. This will cause the resin to settle in the corner while letting air bubbles out. Once I feel its shaken/leveled, continue to pour. (this has been tested and worked successfully)
Problem: There are little tiny bumps on the handle itself. This is caused by air bubbles in the mold because of the way i made the casting.
Solution: Although it wasn't intentional, I may leave it. Because the handle will be treated with a leather wrap, it will give the leather more to grab on and adhere to. If I do decide to get rid of them, it is a simple fix by reconfiguring the casting order/pattern.
Problem: The thin wall at the top of the handle has an obvious cast line.
Solution: Reconfigure the Casting line.
Problem: Tabs still have some flexibility. This could be a possible problem, but more testing will need to be done.
Solution: I still want to add more material to eliminate uneccessary undercuts as well as strengthen the tabs base. This will make a stronger post for the mounting tabs, make it easier to cast, and more rigid (not sure if thats a pro or con yet) In addition, different types of resin still need to be tested to find the right properties, shore hardness, tensile strength etc, etc, etc!
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