Using plaster to make custom molds
Using plaster molds can help you make a duplicate, or even multiples, of almost any object. You can use plaster molds to make copies out of plaster as well as metals. It is a somewhat lengthy process, and it is one that will take time to improve your skill. Therefore, it is best to start off making molds of smaller objects. Then when your skill improves, you can start taking on more complex mold making projects.
Instructions
1. Locate either a cardboard box or a wooden box frame. You want to ensure the sides are high enough to hold one inch of clay along with half the height of the molding object plus two inches of Plaster of Paris. Make sure your box is at least 1 1/2 inches wider and longer than your molding object. If you are using cardboard boxes, have two identical boxes or if you are using a wooden frame, then use one that does not have a bottom or one that can be disassembled and reassembled.
2. Cover the object you want to make a mold of with a thin coat of petroleum jelly. Make sure you cover all the cracks and nooks since the jelly is a release agent, which will keep things from getting stuck later on.
3. Add enough clay to embed one-half of the object's thickness as well as leaving 1/2 inch of clay beneath the object. Smooth out the clay's surface, but do not let the clay dry out. You can use moist paper towels to keep it from drying. Form a 1/4-inch clay rope and put it off to the side of your box. It will be the filler for your mold's hole.
4. Take the petroleum jelly, and this time coat the edges of the mold. Using the jelly will help keep the Plaster of Paris from sticking to the molding object as well as the box's edges, but it will not keep the plaster from sticking to your clay.
5. Follow the manufacturer's instructions on the Plaster of Paris. Your mixture should have a consistency like thick pancake batter. Be sure to tap the mixture several times to release air bubbles.
6. Pour the Plaster of Paris so it covers the molding object and is one to two inches thicker than the object. Follow the plaster's manufacturer's instructions on cure it.
7. Take the cured plaster out of the box. If you have a cardboard box, you might have to tear the box away from the mold along. Use a thin-bladed knife to pry the plaster off the clay. Be sure not to force the object to have it release.
8. Take the mold and turn it over. Then place it back into either the wood box you used or a different cardboard box with the same dimensions. Take the object you want to mold and place it in the half mold. Cover the mold, the object you are copying and the box's side with petroleum jelly.
9. Pour in Plaster of Paris and then allow time to cure. After it is finished, one again use a pocket knife to pry the two halves apart. Gently, work the objects out of the mold.
10. Put the two halves together with either rubber bands or bungee cords. Then pour Plaster of Paris into the hole. Allow time for the copy to set before moving. Once you take the halves back apart, you will a duplicate of your original item.
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