Gareth’s 2010 post about Petaluma, CA, propmaker Shawn Thorsson’s insane HALO costumes was one of our ten most-trafficked posts of the year, so when Shawn sends in a link, we sit up and take notice. This time it’s a ray gun propcasting project featuring one of the pistols from Mass Effect 2. Among other clever tricks, Shawn shows you how to recycle old, cured molds to use as filler when making new ones, thereby saving on expensive silicone. [Thanks, Shawn!]