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Hello,
I have few boxes of Skitarii Vanguards that I'd like to customize, but there is problem - their guns. I hate radium weapons design, they look kind of bent to me. I tried to find some weapon I like the look of and noticed that arc rifle without all the ugly coils and stuff looks like a badass, futuristic but still steampunk tommy gun. The problem is that there is only one of this gem in a box and they are not available in any bits store I checked (not to mention the horrendouse price). Would it be OK to just make a mold of it even though I barely changed anything or should I keep looking and find myself alternative?

This is for your own use and not for resale so it appears "ok".
You modified it so it does lend some case to casting.

I had used the same reasoning way back when they did not have thousand son heads so I kit-bashed and sculpted some heads I wanted and cast them.

I think of it as "If GW does not sell it and it is for your own use, go for it.". It is the least of ethical issues.

I am sure GW would say you need to buy all the kits to get that piece to convert, which I will withhold my answer to that.

Its for personal use so you can do what the hell you want. =P

No you can't. Presumably copyright sculptures are not allowed to be copied without permission for use whether personal or public.