Build a containment box to accommodate the original. Spread a 1/2'' bed of non-sulfur clay along the bottom of the box.
Place the original into the box. Build clay around the original until one half of the piece is embedded.
Using clay sculpting tools, cut registration keys into the clay bed.
Add additional keys. Keys help the two-part mold stay properly aligned from cast to cast.
Spray Ease Release® 200 over all surfaces where rubber will be poured.
Weigh out Mold Max® 30 Part A. The appropriate mix ratio is 100 Parts A to 10 Parts B by weight.
Weigh out Mold Max® 30 Part B.
Dispense Part A into mixing bucket.
Add Part B to mixing bucket.
Thoroughly mix material until there are no color striations in the rubber.
Vacuum degassing minimizes bubble entrapment in thick silicone rubber.
Pour Mold Max® 30 in a long, thin stream over the original.
Continue pouring until the highest point of original is covered with at least 1/2'' of silicone.
Once the rubber has fully cured, remove the clay and place the block back in the box. Do not remove the original!
Spray Ease Release® 200 over the entire surface. This will allow the silicone to separate from itself.
Mix and pour a new batch of rubber. The highest point of original should be covered with at least 1/2'' of silicone.
Once the rubber has fully cured, remove the original model from the mold.
Use adjustable straps to clamp the mold together. Wooden boards prevent the straps from deforming the rubber.
TASK® 13 is a semi rigid urethane resin that is mixed 100 Parts A to 120 Parts B.
Combine Parts A and B and mix thoroughly.
Pour TASK® 13 into the Mold Max 30 mold.
Once the resin has fully cured the mold can be peeled away from the reproduction.
Finished casting is flexible and much safer for stage than the solid wood original.