Saturday, May 31, 2014

09 Plaster Production Molds Nº 61




I stored the new mold in a less traveled corner of the studio, behind the furnace, up on a couple of sticks of wood, for better air circulation. I will put some heavy-duty rubber bands around it before I turn it over. Wow !!! It took all this time to make two four-piece molds of the carving wax feet. Not all the molds for this doll will be this complicated. I tried two different ways to make the two molds. Of the two ways, I like the results of the second mold much better than the first mold. Nevertheless, I have documented about making a plaster build-up, even if it was not the best way to make the first foot. I may be able to use that method with some of the other doll parts? There are a total of 16 doll parts to mold, in total, counting the skull cap as an individual part. I have now finished two of the sixteen molds, so there are 14 doll parts left to mold. I try to do a little bit of work on my doll every day. Click on any image to enlarge it.






I found a new 2-Quart plaster mixing bowl at the local Tractor Supply for $3.99 + tax. I believe it is supposed to be used for feeding farm animals of some kind? Anyway, it is made of thick, heavy, flexible rubber. If plaster dries inside the mixing bowl, I can flex the bowl to get the plaster out. The bowl tares at one pound, so when I mix plaster, I must start counting from one, not zero. I think the nested set of four plastic mixing bowls that I was using cost about the same as this one bowl. The plastic mixing bowls have lasted for years, but are starting to crack, so I thought I would invest in a professional quality plaster mixing bowl. It should last for the rest of my life as a plaster mold maker.






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Friday, May 30, 2014

09 Plaster Production Molds Nº 60




I cut the spare and beveled the corners of the mold. I used the Surform tool to bevel the corners and square-up the mold sides. I used the fettling knife and the paring knife to cut the spare. I used the pencil to draw the lines fir cutting the spare.






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Thursday, May 29, 2014

09 Plaster Production Molds Nº 59




Here are some snapshots I took of removing the carving wax foot from the plaster mold. Click on any image to enlarge it.



I still need to square the sides and bevel the corners of the mold with the Surform tool, and carve the spare.



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Wednesday, May 28, 2014

09 Plaster Production Molds Nº 58




I cut some pieces of 1/4 inch thick wood to raise the coddles up a wee bit. After sanding them, I placed them around the base of the mold, then clamped the coddles securely in place. I rolled out some oil-clay coils and secured the coddles to the mold table. I brushed the mold with parting agent. Click on any image to enlarge it.






I have a lined trash can to pour excess plaster into. I have a bucket of water to rinse off my hands and tools. I got out my mixing bowls and measured water and plaster. I mixed them together, as I have described in detail in previous posts, then poured the plaster into the coddles with the mold table vibrator on. Never pour plaster (dry, set, or wet) down the drain pipes. I always let the plaster setup for at least an hour, but usually much longer.






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Tuesday, May 27, 2014

09 Plaster Production Molds Nº 57




I did not have too much time to work today, but I was able to cut the registrations keys for the next mold piece. I use a homemade key cutter. It is a flattened tea spoon with a large aluminum gutter nail attached to it with Duct Tape.






The keys cut, with the plaster shavings removed.






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Monday, May 26, 2014

09 Plaster Production Molds Nº 56




I took the coddles off the mold, and the oil-clay coils off the molding table. Then I used the Surform tool to level the newly poured piece. Click on any image to enlarge it.






I flipped the mold over and removed the plaster build-up.






Then I removed the oil-clay build-up.






I placed the coddles around the mold to see how much I will need to raise them up so I can pour a 1.5 inch thick bottom piece. I will need to raise the coddles up about one quarter of an inch.



I still need to carve some registration keys, and soap the mold before I am ready to pour the last piece.




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Sunday, May 25, 2014

09 Plaster Production Molds Nº 55




I get everything ready to pour the third piece of this four part mold. Being prepared takes a lot of stress off making molds. I have a lined trash container ready to pour excess plaster into. I have a bucket of water ready to rinse off my hands and tools. I have a scale to weigh water and plaster in a 2:3 ratio. I have mixing bowls and a sifter, and a scoop. My mold table has a vibrator attached. So I soap the mold first with a 50/50 mixture of liquid soap and water. Then I clamp the coddles around the mold. I secure the coddles to the mold table with some coils of oil clay. Then I weigh out one pound of water. I sift 1.5 pounds of plaster into a bowl, then add it to the water quickly and evenly. I let it slack. I push the island of plaster below the surface and squeeze out the lumps with my fingers. I stir the mix until it is smooth and creamy. When I can draw an S in the surface and see a trail remaining, it is time to pour the mold. Click on any image to enlarge it.






I turn the mold table vibrator ON. I pour the plaster into the coddles evenly until the area is full. I turn OFF the mold table vibrator. I pour the excess plaster into the lined trash container. I rinse the mixing bowl and my hands in the bucket of water. Never put plaster (dry, set, or wet) into the drain pipes. I leave the plaster to set for at least one hour.






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Saturday, May 24, 2014

09 Plaster Production Molds Nº 54




Today I used the Surform tool to square-up the mold. I used the fettling knife to clean-up the oil-clay build-up residue. I used the flattened spoon to carve a registration key. Click on the image to enlarge it.






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Friday, May 23, 2014

09 Plaster Production Molds Nº 53




I removed the coddles, the oil-clay coils around the bottom of the coddles, and the oil-clay build-up. I will not have to make any more oil-clay build-ups for this mold. Click on the image to enlarge it.



Next thing to do is to clean up the pattern, and use the Surform to square the mold.




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Thursday, May 22, 2014

09 Plaster Production Molds Nº 52




Today I soaped the mold, put the coddles around it and clamped them securely, pressed oil-clay coils around the base of the coddles, measured water and plaster, and mixed them together. Click on any image to enlarge it.






Then I turned on the vibrator, poured the mold piece, turned off the vibrator, dumped the excess plaster in the lined trash can, then rinsed out the mixing bowl and my hands in the bucket. Never put plaster (dry, set, or wet) down the drain pipes.






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Wednesday, May 21, 2014

09 Plaster Production Molds Nº 51




I thought I was ready to soap the mold and put the coddles around it. Then I saw some more places that needed work. So I worked on getting those fixed. It is a good idea to rotate the mold around when working on it, so as to let light light hit it from different angles. I had been working from one place for a long time, and it looked like everything was good. When the angle of light changed, I saw more work to do. I try to do it right the first time. Getting it done properly now will save time later on. Click on the image to enlarge it.






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Tuesday, May 20, 2014

09 Plaster Production Molds Nº 50




I cut off the end of the oil-clay build-up square, using a combination square and my paring knife. Click on any image to enlarge it.






I continue to try and make the surface of the build-up as smooth as I can.






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Monday, May 19, 2014

09 Plaster Production Molds Nº 49




A work-in-progress snapshot of the oil-clay build-up for the second mold piece for the left carving wax foot. Click on the image to enlarge it.






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Sunday, May 18, 2014

09 Plaster Production Molds Nº 48




As much as I dislike this type of work, I did some scraping on the face of the toe piece of the foot mold today. The best time to fix things is before a new mold piece is poured. I hope I made some improvements. Click on the image to enlarge it.






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Saturday, May 17, 2014

09 Plaster Production Molds Nº 47




I continue to clean up after making the first piece of the mold. This is what it looks like before I started. Click on any image to enlarge it.






This is an in-progress snapshot after I worked on the mold for awhile.



I need to finish the clean-up, then start making the next oil-clay wall for the second piece of the mold. A third oil-clay wall will not be needed because the first two mold pieces and the coddles will contain the plaster for the third piece. The fourth mold piece will be poured over the first three mold pieces and the sole of the carving wax foot. I am going to carve the spare, like I did with the last mold.




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Friday, May 16, 2014

09 Plaster Production Molds Nº 46




I removed the coddles. Click on any image to enlarge it.






I removed the oil-clay.






I cleaned the oil-clay in water.






I cleaned the oil-clay coils.






I started to clean up around the carving wax foot.



I will finish cleaning around the carving wax foot, then I will build another oil-clay wall for the second mold piece.




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