Looking for a moldable plastic

[Frangibility]

Hi, folks. I'm a frequent reader, rare poster, and I really appreciate this site.

Anyway, I'm looking for a material that I can use to make a fist-sized bundle that will simultaneously hold a Surefire flashlight, an Asp pepper spray (kubaton-style, that shoots spray out of one end parallel to the body), and a sharper impact weapon that passes the P.C. test, such as a Cross pen. I'm hoping there is some kind of hobby material that I can use to mold something to the shape I want before it hardens (or gets hardened in an oven?). I hope this material will be tough when hardened, rather than brittle or soft.

The point of course is to facilitate holding both a tac flashlight and a defensive spray in the same hand. For a CQB impact weapon, I'd like it to have an impact surface, or accept an object into it like a Cross pen. Of course, the flashlight could be a Surefire E2D with the crennellated strike bezel, but I'd be very happy if a less evil-looking setup could be found, so I wouldn't have to worry about it being confiscated at checkpoints. Without the flashlight, spray, or pen inserted into it, it should look just like a blob of plastic with finger ridges -- kinda like a handlebar grip for a kid's bike.

I think there must be some kind of compound out there that fits the bill. Any ideas?

Thanks,

Frange

 

[rcmodel]

Only thing I can think off right off hand would be Bondo auto body filler.

It's relatively cheap, has a reasonable working time, and can be molded to anything you can dream up. A steel or aluminum pin or bolt could be molded in for a hard striking point.

You can wear a plastic or latex glove to squeeze it to fit your hand.

Any additional trimming or fitting after it cures out can be done with a Dremel tool and sanding drums.

There are epoxy puttys that are tougher & stronger, but cost way more then Bondo.

I suppose you could use Bondo to perfect the design, then make the last real good one out of epoxy putty after you lean how.

rc

 

[SDC]

A sheet of moldable Kydex might work for what you're looking for, but you have to heat it up (toaster-oven?) to get it to the shape you want, and you may have to use pop-rivets to get it to stay in the shape you want.

 

[hso]

Kydex can be heated in boiling water or in a cheap toaster oven. Why "cheap"? Because you want to pick up throw away at the thrift shop so you can run it in the garage because of the stinky fumes.

 

[TAB]

there are lots of plastic that would fit that bill... so the real question is, what tools do you have at your disposal and what is your skill level?

 

[bobby n.]

having worked in a plastics moulding plant, i say find some old clear scratched up beat up plastic tops to a blender, hamilton beach the best, and grind them up. take a metal pipe
and place a brass cap on the end and a second smaller metal pipe as a plunger and place the contents of the plastic inside an place the plunger in like a syring, and make the mold out of clay or metal and force molten plastic into the mold using a hydraulic press after its heated up to about 600 degrees. letit cool. pop the mold open and youll have what you need