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Tue May 27 16:38:55 CST 2014
If you want to create many copies of an object in gelcoat fiberglass, you will need to make a mold of that object. Since fiberglass is hard, you will want a mold that is soft and can flex off of each copy. The ideal material to do this is silicone. It is strong enough to produce many copies, but soft enough to be removed from any corners or angles the copies may have.
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Instructions
1 Seal off the ends of the U-beam with duct tape.
2 Mix a small batch of silicone according to its directions.
3 Pour the silicone into the U-beam and allow it to cure.
4 Cut the long strip of silicone into small pieces. These pieces will act as keys to help the silicone mold lock into its hard outer shell.
5 Glue the object to be molded to the working surface.
6 Brush a layer of mold release onto the object if it is made of a porous material like plaster.
7 Mix a small batch of silicone according to its directions.
8 Apply a thin detail coat to the original with a paint brush. Tap silicone into all of the nooks and crannies. The thinner this coat is, the less chance there will be of surface air bubbles.
9 Allow the surface coat to fully cure.
10 Mix a larger batch of silicone.
11 Apply the second batch of silicone to the object much more thickly. This will form the bulk of the mold. Continue brushing it until it thickens enough that it will stay put. Be sure to fill in any pits or undercuts and soften sharp angles.
12 Lay several of the keys onto the silicone and press them in just enough so they stay put.
13 Allow the second coat to fully cure.
14 Make a hard outer shell to support the shape of the flexible silicone. This can be done in plaster bandages if you don't need it to last long. For a more permanent mold, use fiberglass bandages, or the same fiberglass you will use to make copies out of.
15 Remove the original from the mold; it is now ready to produce copies. The silicone mold can be separated from the outer shell, then pressed back in place because of the keys.