This is an extensive thread covering several aspects of making a model shell from scratch. There are many parts to this thread that david f. has posted and all of them can apply to all scales. This model is in Z scale, but the procedures for casting david f's Z scale shell apply to all scales for this type of casting. At this time, the thread is on-going; I suggest you link to it and participate as the more questions, the better. This picture is from the thread and will be updated as the thread progresses. This photo is about making the molds with RTV rubber. I will add that there are other types of casting methods. Hopefully they can be covered in other threads.