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Jack Knight1979 Profile
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Apprentice
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Registered: 02-2004
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Making a Plaster Mold


Hey Y'all.
I'm thinking about making a two part plaster mold. Does anyone have any pointers for me? How much Ultracal30 will I need to make a cowl??? I haven't started my sculpt yet. I want to get an idea what this will cost me first. Clay, plaster, time, etc.

Is there a mold release you guys recommend?

Thanks for you help,
Nickoli

Last edited by Deadly Lemur, 3/19/2006, 12:09 am


---
Regards,
Nickoli
www.c4-designs.com
10/14/2004, 4:09 pm Link to this post Send Email to Jack Knight1979   Send PM to Jack Knight1979
 
Apocalypton Profile
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Re: Making a two part plaster mold


Artsee1 is a great expert on this. See if you can get some info from him.

 :signal
Zane

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As a symbol, I can be incorruptible. I can be everlasting.
10/14/2004, 6:57 pm Link to this post Send Email to Apocalypton   Send PM to Apocalypton
 
The BlackBat Profile
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Re: Making a two part plaster mold


I'm hoping that some of the experts jump in with a good answer for this one... :hey

~Tim :batfly

---
"We all walk in the dark and each of us must learn to turn on his or her own light."

10/15/2004, 12:46 am Link to this post Send Email to The BlackBat   Send PM to The BlackBat
 
cursedbat Profile
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Re: Making a two part plaster mold


First pointer I can give you is if you can get around it don’t use a head to sculpt on that is stone. Either try to get a foam head or use a clay head both poured from a lifecast.

Dont do a 2 part mold do a one piece mold.

The reason I say this is because you will be saving yourself all the trouble of seams which are unnecessary. They only make your job tougher and the finished product less perfect. And why do that if you don’t have to.

With a clay lifecast you can just do a one-piece UC30 mold and dig out the clay. If you go the polyfoam route just flip the mold upside down and burn out the core again, no seams.

Now if you don’t have any experience with either 2 part or one part molds you are about to take on a huge task. Using UC30 is not something most can just do. You will find that it is just like anything worth while, it is something that needs to be mastered. I have seen many people ruin their sculpts because they did not take time to master it and underestimated the technique needed for it.

Practice with it and learn the steps its worth it. I know that there have been several discussions on this. the way I do it is I weigh out everything first. The guide lines say to go about 3 parts mix to 1 part water but I personally don’t like that wet of a mixture. I go 3.5 lbs mix to 1 lb water by weight.

Get yourself a good container which should hold 2/3 of the mixture. Now invest in a Hanson mix head for your drill. Get the size that corresponds with the size of your container. For a small batch say a gallon bucket use a 3" head. For a 5-gallon bucket you will need the 5" head. They are cheap just do a google search and they mix like no other.

Now get a timer. I know all this seems like a lot and we may tend to want to cut corners, but all these steps will be worth it. Put your water into the container and sift not dump, sift the mix slowly into the water. Watch the time and let this sit and absorb the water for about a minute.

Now take your drill, make sure it’s a high-speed drill, and put it in the mix at a 15-degree angle. Mix for 1 minute and a half. Than move the drill to the other side of the container and mix for another minute and a half.

This time can very with temperature and mix but what you want to watch out for is the mix wetting out. What this basically means is if you take care of business this mold will be hard as hell and will give you an incredible amount of pours.

Now the main thing to remember at this point is you are fighting time. The mix must be applied before it starts to thicken and you want to get all the detail. Application is a book in itself.

I'm going to skip some steps because it has been covered but get that first coat down and as you apply the next coat with burlap or even better sisal, make sure, make sure not to push into your first coat. This will give you a bad result to say the least. Finish off with the beauty coat and that’s that.

I know guys that will go in and just lay down a really thick first coat and just let it set. Then finish. Other guys that lay a super thick coat, a sisal coat and beauty and that’s it. Its something you got to get down for yourself and if you haven’t done allot of it, than don’t risk your sculpt on a first or even second try. Practice on something you don’t care about to get used to the materials.

If you have to do a 2 part mold its just a matter of walling it up, using keys and a release agent for the two UC30 halves. The clay can be crysal cleared, it needs no release, and there are things that make application easier like puting the sculpt in a craddle and on and on. Hope this helped.

Last edited by Deadly Lemur, 3/27/2006, 3:05 am


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Dont disrespect the archetype with the pathetic sides of the human condition


10/15/2004, 5:15 am Link to this post Send Email to cursedbat   Send PM to cursedbat
 
artsee1 Profile
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Re: Making a two part plaster mold


I used to carry my teacher's video but I am out currently. If you will go to [sign in to see URL] and ask for "The Art Or Creating Latex Masks" By Carl Zundel on vhs all your problems will be solved forever regarding this issue.

Paul

Last edited by The BlackBat, 10/16/2004, 1:34 pm


---
"There is no spoon"
artsee1.com Home of the Original One Piece Muscle Suit.
Email: artsee1@earthlink.net
Visit me on my Bat Costuming Board- Behind The Mask http://behindthemask.yuku.com/forums/1/Behind-The-Mask#.UA1Xzo6kLzI
10/15/2004, 7:19 am Link to this post Send Email to artsee1   Send PM to artsee1
 
cursedbat Profile
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Re: Making a two part plaster mold


Most of the facts for mix which is 90% of most peoples end problem when really trying to refine the work and get a mold that is made from the best material that will give you the longest lfe, I found just through researching with usgypsum and listening to others plus good old experience.

There are allot of videos out there anyone of them will help allot but they always leave somethings out. I suggest getting one and of course talking and listening to others experience. Thats why this place is so great. I always learn the most when I think I finally know it all.

Last edited by The BlackBat, 10/16/2004, 1:36 pm


---
Dont disrespect the archetype with the pathetic sides of the human condition


10/15/2004, 1:38 pm Link to this post Send Email to cursedbat   Send PM to cursedbat
 
Jack Knight1979 Profile
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Re: Making a two part plaster mold


Thank you very much for your advice. Just what I was looking for. ;)

---
Regards,
Nickoli
www.c4-designs.com
10/15/2004, 2:14 pm Link to this post Send Email to Jack Knight1979   Send PM to Jack Knight1979
 
The BlackBat Profile
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Re: Making a two part plaster mold


Anyone have any tips for Nickoli if he can't manage a 1 piece mold. Maybe tips on getting a smooth dividing wall, particular materials to use,coating your sculpt, mold release, mold locks, the list goes on and on....

This can be a very informative thread, and we've got a ton of people in here who should welcome this chance to step up and give some pointers. This is exactly the type of thread we need in the archive sections that can help newcomers achieve their goals and experience the thrill of creating their own suit themselves. :up

~Tim

Last edited by The BlackBat, 10/17/2004, 2:01 am


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"We all walk in the dark and each of us must learn to turn on his or her own light."

10/16/2004, 1:51 pm Link to this post Send Email to The BlackBat   Send PM to The BlackBat
 
artsee1 Profile
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Re: Making a two part plaster mold


Water based clay on top of bricks or boards to get it to the right height while saving costs on materials such as the clay is a good way to go. Keep the dividing wall as much of a right angle as you can and allow at least two inches from every side for added strength. I recommend coating your sculpture with or Krylon crystal clear. Later when you flip it over or while doing the first side remember to place little clay wedges every few inched along the edge of the dividing wall to allow for ease of prying apart with a screw driver later. Make sure to coat the plaster edge well with vaseline prior to laying the plaster for the other side on top of the fresh plaster dividing wall.

Paul

---
"There is no spoon"
artsee1.com Home of the Original One Piece Muscle Suit.
Email: artsee1@earthlink.net
Visit me on my Bat Costuming Board- Behind The Mask http://behindthemask.yuku.com/forums/1/Behind-The-Mask#.UA1Xzo6kLzI
10/16/2004, 2:02 pm Link to this post Send Email to artsee1   Send PM to artsee1
 
The BlackBat Profile
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Re: Making a two part plaster mold


Good info :up Anyone else?

~Tim :batfly

---
"We all walk in the dark and each of us must learn to turn on his or her own light."

10/17/2004, 2:03 am Link to this post Send Email to The BlackBat   Send PM to The BlackBat
 


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