What casting material is best for flexible parts? Like for instance Spy Troops masks/helmets and the lower arms of VvV and Spytroops?

good question...lots of casters won't help with that one

I know that Polytek sells urethane casting rubber. (most urethane rubbers I've seen are for mold making) I've been wanting to get some, to try casting hair. But I have no idea how soft the stuff is, or if it would work for what you want.

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I would avoid Polytek... Everything I've read about them is bad... mostly because they're a Mercury Catalyzed reaction...so the Rubber contains Mercury...better to avoid this brand.

I think the Majority of people from the GI Joe Customizing world use Smooth-on Products.

Guys like Alyosha and Ragin'Spoon use Smooth-on's Clear Flex: http://www.smooth-on.com/Urethane-Rubbe ... index.html

Again... be sure you read all the safety postings...both Clear Flex and Crystal Clear from Smooth-on can be pretty nasty...be sure you're properly set up to handle the material.

Last...and what I would say is the best option is Smooth-on's Task 16 http://www.smooth-on.com/tb/files/TASK_16_TB.pdf It has plenty of flex...is nice and soft...and can be colored as needed... the only issue is the 6min working time...it is really quite thick and not the easiest material to fill molds with.

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Having used both, I still prefer Polytek's resin over Smooth-On's. The amount of bubbles I get in the Smooth-On resin is ridiculous.

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Thank you very much for the info gentlemen!

Beat me to it..

This cannot be overstated especially regarding the latter. Crystal Clear and Clear Flex require an N95 rated respirator (not just something to cover your mouth and nose) and even then you should be mixing this material outside whenever possible. Even when working with miniscule amounts (say the size of a gi joe head) the fume by product is noxious , dangerous and cancer causing. And you *can* absorb the harmful chemical through the skin. 2 people that i know of, one that i trained , have had very delayed but eventually bad skin reactions due to constant unprotected contact with the materials. Not heeding the warning regarding using safety gear caught up with them.

And mercury poisoning is irreversible. Check any documentary about "3rd world" country citizens who work with mercury often and that should be enough to make you choose another option (and to stay away from certain fish).

Thanks for all the safety warnings, I will definitely be safe when working with whatever I end up using!

Anyone want to take a guess as to what material Hasbro uses for the spytroops helmets/masks/lower limbs? The purpose for this question is that I am planning on making an "aftermarket" Flint / Serpentor Spy Troop, and an Iceberg / Snow Serpent.