The original brass shower door handle, over time, cracked and broke. The homeowner contacted the door manufacturer for a new one and was informed that the handle was discontinued, however a custom replacement could be purchased from another company. The cost of the replacement handle was substantial. A replacement "Cold Cast Brass" handle could be molded and cast with Oomoo® 30 silicone rubber, Task® 9 performance casting resin and Brass Metal Powder for a fraction of that cost.
The original brass handle, over time, cracked and broke.
Broken brass shower door handle.
A sister handle is removed from another door to use in making the mold.
Gather all supplies needed before you start.
A plastic deli cup is cut to size for the mold container.
Aluminum foil will be used as a base for the mold container.
The good handle is hot glued to the aluminum foil by applying a bead of glue around the outside edge.
The handle is firmly pressed onto the center of the aluminum sheet..
The deli cup is centered around the handle and glued down. The mold container must have 1/2 inch clearance on all sides, including the top.
Safety First. Wear vinyl gloves when working with these materials.
Read the Technical Bulletin before using these products.
Carefully measure required amount of Oomoo® 30 Part A.
Measure out and equal amount of Oomoo® 30 Part B.
Combine Part A and B into a mixing container.
Mix thoroughly until a uniform color is achieved and no color streaks are visible. Scrape sides and bottom of the container to ensure a good mix.
When no color streaks are visible, transfer mixture to a 2nd clean mixing container.
Mix thoroughly for an additional 1 minute. Make sure no color streaks are visible.
Slowly pour silicone around the handle.
Liquid silicone should completely cover the handle by 1/2 inch over highest point.
Oomoo® 30 requires a minimum of 6 hours to cure.
Once the Oomoo® 30 is cured, remove the aluminum foil from the base.
Gently remove the mold from the container.
Gently remove the handle from the mold.
Oomoo® 30 silicone mold rubber captured perfect detail and is ready for casting.
Gather all materials needed to make the casting before you start.
A measuring line is marked on a small cup. Very little material will be required to make this casting.
Brass Metal Powder is measured to the line.
The Brass Metal Powder is dispensed into the mixing cup.
Using the same measuring cup, carefully measure Task® 9 resin Part B to the line.
Pour Task® 9, Part B into the mixing cup containing the Brass Powder.
Thoroughly mix the Part B with the Brass Powder continually scraping the sides and bottom of the cup while mixing.
Carefully measure Task® 9, Part A.
Pour Part A into the mixing cup containing the Brass Powder and Part B.
Mix thoroughly scraping the sides and bottom of the container several times.
Slowly pour the liquid mixture into the mold cavity until completely full.
Allow the resin to cure a minimum of 60 minutes before demolding.
A drill is used to carefully clean out the screw holes.
Steel wool is used to polish the cast replacement handle.
The handle is attached to the shower door.
The new handle perfectly matches the shower door trim.