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Hi, I have a old japanese model kit from the 1980s that comes with a gun about the size of a bolter I guess, and its made in the harder model plastic as opposed to what GW makes their kits with. This kit is way way out of production and the likelihood of my finding another gun (I need multiple) is pretty much nil. I was hoping to see if there was a easy DIY modling kit I could buy that would help me make about half a dozen copies. Anyone have any suggestions?

I was hoping that the mold would be close to the weight of plastic, but I am not sure resin would work as in my experience resin seems to be a little fragile when done in thin pieces. I would be fine using some kind of metal, but I dont want something too heavy like lead.

The simplest option I would suggest is to get hold of some Oyumaru. It's also sold as instant mold (for a bit more money).

It's a re-usable silicone-based moulding material. Drop it in hot water for 3mins and then press around the object either in 2 steps or in one and then cut in half, to make a two-part mould.

Remove the original and then press in some GS or similar putty.
Repeat.

The copies won't be plastic, may be slightly heavier, but you won't get an easier method.

and then you can keep the Oyumaru to replicate anything else in the future.

Although it is the "gateway drug" of the casting world and will soon lead to you making your own models and casting with "proper" silicone and resin.

haha many thanks will look into it!

Any ideas on the best place to order it?

Actually found it on amazon, that works!

Also, I did find a demo of it:

http://gravengames.co.uk/making-molds-with-oyumaru-instant-mold/

and yes it looks great when doing a Dreadnought's foot, but the part I am trying to re-mold has some thin parts that I am not sure would hold up well using green stuff, like the barrel of a gun.

Something thin like the barrel of a 40k sniper rifle. Any thoughts on what material I would use for that?

Yeah, I got some of ebay (all the way from china and still cheaper than buying local), but amazon works too.

Moulding thin parts is always tricky. This is where plastic shows it's strength (pun not intended).
Resin, as you mentioned, is quite brittle.

Green stuff though, is pretty flexible and so won't snap so easily. Over the length of a gun I don't think it'd droop at all.

However, you could always mix in something like Milliput (which I believe is tricky to get hold of in America) that is much harder than green stuff. It too is a bit too brittle for thin parts, but a mixture of GS and Milliput has the benefits of both, solid enough for working with (like sanding), but flexible enough to not be brittle. A bit like plastic.

You could also, embed a short length of paperclip (or other stiff wire, like you would use to pin a model's arm on) within the cast when you push the putty in. That would make them suitably tough.

If you have some GS to hand, try it out. Make a roll of the thickness you want and then see if it's strong enough for your needs.

Thanks for all your help! Will do further research!

No prob'.
There's a few tutorial/information threads here on DDakka that cover the various types of casting.

and I have my thoughts and exploits around moulding and casting spread through my "money making" blog also. Casting from about page 2: http://www.dakkadakka.com/dakkaforum/posts/list/549077.page#5997978

My first impressions on Oyumaru was in my army blog from here onwards: http://www.dakkadakka.com/dakkaforum/posts/list/1440/471119.page#6131392