Would any of you guys have any tips that would work best to rid this thing of the shmutz on the top side of the tube? This is a proof cast from Darth Stone that suffered some mold failure. Had little pieces of foam and rubber down In the seam along with resin but I worked the soft stuff out. Have been going at it gingerly with needle files, but I'd love to hear any more ides from you guys that have been down this road before. Other than several small air bubbles to clean/fill, the cast was in pretty damn good shape, though the tube areas in general look like Fido's ass.

You might consider some Apoxie Sculpt or some red Bondo glazing putty.

Dave

Is there any other method for removing more of the material out of the crevice? I still need to get more gunk out before I fill it.

Try a dremel type tool, just be very careful.

What is the nature of the schmutz? This is more gelcoat/resin correct? I would be using a combination of sandpaper and curved exact-o blades to shave it to the correct shape.

Dave

...A bandsaw would get rid of that shit in hurry...

Was going to attempt to NOT use my bandsaw.
Dcarty- it is resin. Maybe I could use my little exacto knife to work it out of the groove. Going to have to be built back up some to regain some shape there, just trying to not fill too much of the space in so it maintains reasonably correct appearance.

i would say try a folded piece of fine sandpaper and use the edge to work the stuff away. Resin from my limited experience will sand down to a powder fairly easily and smoothly.

Thanks guys! Shmutz is eliminated! I used a needle file initially to get the high points worn off, then used a small modeling knife to continue working into the groove.
Finished it up with 320 sandpaper folded working it slowly and carefully....this was cast in that epoxy resin with FG cloth inside, and I will say it's a much harder material then the typical gelcoat or resin on other lids I've seen.

I then used some filler to level out the groove so it's consistent throughout the area between the tube and face, and I'm pretty happy with it. I'll post a few pics once I get it(filler)sanded down. The mask still needs several high spots sanded down too, as this was a proof cast and basically proved that his mold was not quite ready....Still glad I got it though and will make a fine ROTJ display.