Ok guys I have no plans to mold a pack shell but i was wondering something. Why do all the pack molds I see not have the Ion Arm, Filler Plug, and Beam line molded on them. I mean I’ve even seen ones that have the Booster and PPD molded in, so wouldn’t it just be easier to have it all one piece and also make it not so worry some about having to secure you ion arm when you go to parties and conventions because its already a part of the pack. I’ve been thinking about this for months and i just can’t figure out why someone wouldn’t do it, then again I am molding stupid. 
I imagine its very hard to pull a pack out of a mold if it includes the ion arm, it sticks up too high.
It’s a bitch and a half to demold it without those pieces, I wouldn’t even want to attempt getting it out with those parts… I’m getting better but it still takes me about 5 minutes to work the casting out of the mold without causing any damage or undue stress to the casting… You will see many fiberglass pulls cracked in or around the top of the spacer banjo arm, it’s a weak part of the shell and the most complicated area to get released…
So in short skipping those pieces places MUCH less stress on the mold making it last longer and also makes your life as the caster easier…
They got a point, Harry. It’d be in too deep to just bend it and pop it out.
It’s like the last Smartie. You gotta bust open the tube to get it out.
ahh ok. Thanks for the quick replies I didn’t realize how much of a pain demoulding was, I apericiate the simple explanations. and now my curiosity has been satisfied :D. Thanks
I have a one piece mold that has the booster tube already molded in and believe me, it’s a major pain to de-mold. To get the part out, I have to pull the mold from the jacket and fill the sides water, slosh it around, and shake it free. It usually pops right out but without the water, the booster is locked in due to the slight undercut.
Check out Venkman71’s mold over on Proptopia. His made his in 2 pieces that bolt together so it makes separation much easier. Basically, the more pieces to your mold, the easier to de-mold… in theory.