davidbross said:
would that be appropriate and cost effective on a commercial model? I am thinking of releasing my first kit.
I'd do some experimenting with a variety of materials. Some of the finest brick casting I've seen was Hydrocal wall castings in an N Scale kit by Downtown Deco. I've never seen Bondo used so don't know how it compares for detail quality but nothing looks worse than poorly cast brick work.
I'd also try using a two part mold to keep the curve and the thickness uniform. Properly constructed, I think this would be your most cost effective method, reducing your labor, material and the inaccuracies in bending a panel to the correct radius after the fact.
Casting isn't rocket science but it takes a bit of practice to get it right. (I'm still practicing and hoping to get it right someday.) I've been selling some laser-cut wood kits and the main thing I've learned in the process is that people who pay cash for your product rightfully expect the parts to be perfect.
Wayne