You seriously didn’t think I could wait until tomorrow did you?
Yep, I got busy right after dinner and just had to see if all of this work paid off and I could indeed pour some wax tomorrow.
Prior to setting the pieces all together, I sprinkled powder onto the design surface of the rubber mold and gave it a good shake. For those of you who don’t know, this is called powder coating. The reason I do this is because after resin is poured, it gives off a shine that is hard to paint. Powder coating not only dulls the surface but the powder draws the resin into the nooks and crannies. I use baby powder because I’m too lazy to look for talc but talc of any kind is fine.
Next I fit the rubber into wherever it matches the plastic – there are many many register marks on the rubber to help you find where it should go. Once I find where it fits exactly, I start to clamp the various pieces using anything that works – some areas only need hand clamps, some need a tie down and some just need a spot of duct tape. You must do this step quite correctly as if you don’t, your cut seams may lose alignment and your casting material will only coat your floor.
I turn the entire mold upside down and look inside to make sure that there is room between the walls to pour material – if they are touching then you’ve put your rubber in wrong. Note, this is a very complicated object to mold so it must be more precise.
Note, it is hard to tell from the picture but remember there is an inside to this project – the vessel floor is just a little lower than the hole
Then bit by bit I mix and pour my resins. I don’t pour large amounts at once because a large weight of liquid could surely stretch your rubber. Smaller amounts dry without creating weight. I finish my pour just a little higher than the collar to allow for any shrinkage or sanding the bottom should it end up a bit lopsided.
When the resin is completely hardened and the whole item is cool to the touch, I remove all of the jackets and my casting is complete. I was lucky, there were so few trim lines but if there is seepage resin, it is easily sanded off. Do you notice how taking a mold from both inside and out gave such a nice texture to the inside of this vessel?
Then I gave myself a big pat on the back and had a pastry!!!! Tomorrow I will cast it in wax and the next time you see this vessel it will be in bronze.
Just in case you’re wondering – the resin was only a test to see how the mold was working. After seeing it worked, I will now pour WAX into the mold. The wax will be coated with concrete at the foundry then placed into a kiln where the wax will drip out of the concrete and leave a void where molten bronze will take the place of my wax model. This is called the lost wax process. My mold will only ever be used for wax or resin, not anything hot.
Thank you so much for your interest and please feel free to email me if you require any help with your project