Machining Bondo

[Zigmaan]

I have a project that requires intricate 3d machining and must stand up. The base is wood and will have a pocket about 1/4 deep put in under the logo. I will put in undercuts so that the composite epoxy will stay after, and build up the area about 1/4 above the base material. I have a few questions on this.

I am chossing autobody filler (bondo) because it is cheap.

Questions:

1) Will this material stand up, and if not, what is a good substitute?
2) Will the material cut using H.S.S. cutters? or only carbide?


I might think of more questions as we discuss this topic.

[Zigmaan]

I have to finish the model so that the cutter will flow better, instead of dwelling. This will take sonme tim as it is projected onto a cylindrical surface first them built up and tweeked before filleting. I might actuall ask the Fort (historic park) if they will allow me to pull a cast of the original, although, since I have no digitizer....would not make it any easier.

Note that on a 20 inch cannon, this detail is only about 1 x 1.5, and the base material is slowly drying Ash. It is roughed out now, waiting on spring to finish cut it with no logo. I am then intending to pocket the area and insert it. just trying to find the best material.