During 1980-81, Estes was producing the Patrol Cruiser Excalibur. This was a BT60 kit that used the same nose cone as the Der Red Max. 

Then, in 2015, Estes released the Der Red Max as a 4" Pro Series kit! I saw an opportunity to build an upscale Patrol Cruiser using the nose cone from the Der Red Max :)

Instead of doing a kit-bash, I figured I'd had a go at making a mold, so I could produce a few nose cones - and also be able to build the 'Max, too!

Here's the original nose cone and a duplicate made from the mold

Mega Der Red Max - Nose cone Mold   Completed Nose Cone

The first step of making the mold is to make a surround in order to slit the mold in half.

Mega Der Red Max - Nose cone Mold

Under the mold, I've added some supports to help support the nose cone

Mega Der Red Max - Nose cone Mold

Here's the nose cone with the first side of fiberglass done

Mega Der Red Max - Nose cone Mold

Here the mold has been removed leaving the nose cone in place

Mega Der Red Max - Nose cone Mold

And the 2nd half. Why different colours? Helps me see where I have and haven't got resin.

At this point, the mold is done and just needs to fully cure.

Mega Der Red Max - Nose cone Mold

With the mold fully cured, holes were drilled around the flange area and bolted together.

With the bolts in place, the excess materials were cut off with a dremel.

Patrol Cruiser Excalibur 4" Upscale (Build)    Patrol Cruiser Excalibur 4" Upscale (Build)

See the mould used in part 2 of the 4" Upscale Patrol Cruiser Excalibur Build.