The 4 moulded bodies
The 2 packs
The green stuff was easy to work with, as long as you keep things wet! it was very evident when you were mixing it up and your fingers dried out and it gets very sticky. This is where the main issues arose though, the first cast of the body turned out to be far to thick as I put in too much green stuff and couldn't squeeze enough out to get a good mould, the same happened with the pack as well, but to a lesser degree. I changed the process for the next few, filling each half of the mould and then pressing together, this worked better, combined with using a G-clamp on the last few, meant that I the final few casts were pretty good, although they were still a little thicker than the originals. In addition, the moulds were not perfect, as in a few places there was some extra material, this was mainly on the packs, by the antenna part, but this was easily removed.
The extra thickness can be seen on the arm mounting points
You can also see the extra thickness on the packs
The detail on the original was well reproduced though and I think when painted on the table top it will be hard to identify the green stuff parts from the originals, so overall I am very happy with the results. I will be using the process again at some point to reproduce extras and possibly for a few other rare or random parts that are hard to get hold of, but I wound be trying to reproduce entire armies, its far to much work and there is a lot of flash and mould lines to clean afterwards.
Would I recommend the process, yes, I would, but like I say, only for a few little bits and extras. One thing that did surprise me was that all of the detail on the original models was reproduced, as they are very detailed models.
The details on the front of the chest plate. Although not quite as good as the original, but still very good.
Also the details of the vent on the side of the pack. The bolts/lugs on the bottom of the pack didn't come out as well, but their still there.