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We Are All Doomed If This Dude Starts Selling These Huge Mario Kart Shells to Angry Drivers

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  • 1
    Cheezburger Image 8980876032
    Via: Zlurpo
    Start with a block of rigid insulation foam. The pieces are all glues together with "Great Stuff," which is a canned expandable foam meant for filling gaps. It glues foam very well, and doesn't dissolve it like a lot of glues.

  • 2
    Cheezburger Image 8980876544
    Via: Zlurpo
    Make it round. I used a had saw.

  • 3
    Cheezburger Image 8980877056
    Via: Zlurpo
    Carve into the side of it and mark the shape of the outer edge of the shell.

  • 4
    Cheezburger Image 8980877568
    Via: Zlurpo
    Cutting with the saw...

  • 5
    Cheezburger Image 8980878080
    Via: Zlurpo
    More carving with a saw, and with some very sharp 40 grit sandpaper. I was foolish and didn't wear gloves so it chewed up my hand a bit too.

  • 6
    Cheezburger Image 8980878336
    Via: zlurpo
    Shape taking form. I had to add more to the top.

  • 7
    Cheezburger Image 8980878592
    Via: Zlurpo
    Oops I missed some pictures. But it was all carved and shaped with the saw and a couple knifes and some sandpaper. I cut the groves in with 80 grit sandpaper wrapped around a sharpie.

  • 8
    Cheezburger Image 8980881152
    Via: Zlurpo
    Here I've coated the whole thing with gray house paint, and then added some Bondo to the roughest parts to try to smooth it out a bit. Then I sanded the Bondo.

  • 9
    Cheezburger Image 8980882944
    Via: Zlurpo
    I did 5 layers of rubber, then plaster mixed with fibers. This makes a mold jacket.

  • 10
    Cheezburger Image 8980884736
    Via: Zlurpo
    Oops again, lots of steps skipped. So I made the other side of the mold, took off the plaster mold jacket, took off the mold (cutting it around the middle) and then cast the two sides in fiberglass. Then I used fiberglass to put the two sides together. Then paint it white, mask it off, paint the tan and red, and use an airbrush to add some detail shading.

  • 11
    Cheezburger Image 8980887040
    Via: Zlurpo

  • 12
    Cheezburger Image 8980887552
    Via: Zlurpa

  • 13

    And here's a video of it in action!

    Via: Nate Bonham
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