It may be the way to go - some extra expense I assume,

but if cut down on

machining that would be good.
George (down under)

George, As everyone else has said Great Job! The styrofoam process that 
folks are talking about is used exactly to cut down on the machining process. 
The parts come out looking very much like the parts from a permanent mold die casting.

You have already made a VERY NICE looking, probably very useable part. Good 
patterns. The advantage of the lost styrofoam process is that you dont need 
to worry as much about the sand or other mold meterial collapseing and the 
parts can be very close to "final" dimensions while still allowing 
clean-up machining. With the updates you have in mind the cost of doing 
the lost styro. probably wouldn't be worth the cost. You can't recover 
much machining cost on less than 100 parts.
Now that the correct numbers are plugged into the guys cnc you are 
probably best to stay with your current mold and do your improvements. 
Excellent job way ot go. Bill Jepson

 
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