Blanket Mold

Leveling the Mold
Now that we have created this dandy little production mold and back up shell there's one more thing we have to do.  Before we send our brand new creation off into the world  to perform it's function we have to get it to stand up on it's own, straight and level.  If we do not level the mold, every time we pour it, it will produce a casting thick on one side thin on the other.

  One method of instilling in our mold a level headed approach to life is to give it a firm plaster foundation.  Start by spraying your marble work surface with Pam or mold release.  Since we will be pressing the back up shell down onto a small amount of mounded plaster the spraying of the marble with mold release is essential.   Whenever you are placing a large chunk of plaster on a small puddle of wet plaster on your marble the tendency will be for the thinner layer of  plaster to delaminate or to stick to the marble. This is especially true when the attached layer  is to be 1/8" or 1/16" thick.  The way to resolve this is by encouraging the thin layer to grab onto the large chunk of plaster rather than the marble. In essence make it an offer it can't refuse.  Spraying the marble work surface with mold release before  pouring this thin plaster layer on it is the secret of success. 

This same basic process can be used to level statuary items,  plaster models or whatever other plaster pieces may need leveling.   OK here it is. This is the down and dirty quick and easy method of leveling your mold.  Make a thick plaster mix.   Build up a mound of plaster in the center of your  marble or modeling stand with it. 

Squish some plaster into a pile

(In the case of the pineapple back up shell I made two mounds of HydroCal.)   Set the back up shell with the mold in it down on the mound of plaster. Put a level on top of the mold. (On statuary items of course this will not be an option, you'll have to eyeball it.)

Level it

 If the mold is not level wedge screwdrivers or chisels under the backup shell to bring it to a level position.  Work quickly tapping down where it's high and raising with wedges where it's low before the plaster stiffens. When the plaster has set up just enough to hold the weight of the back up shell pull the screwdriver or wedges out.  Instead of steel wedges you can grab some old plaster chips and insert them into the wet plaster.  Push them under the back up shell to bring it up to level.  Leave the chips in the set plaster. They will be cemented in place forever as part of the unit and who will ever know they're there?  I won't tell if you don't!  Trim the new foot you have placed on your back up shell to make it look neat and pretty and you're off to the races.

the High  falutin' fancy way

Another method of making a stable environment for your budding young  upstart of a mold is to attach wooden runners to the bottom of the shell.  This is the deluxe edition of level back up shells.

Level the mold first by placing pieces of plaster under it.  Lay boards alongside the back up shell. 

Dip burlap in mixed White HydroCal.

Run the burlap down the side of the back up shell and over the boards.  Put on several layers and finish the job by smoothing out the final coat nice and neat.  This method makes a strong professional job and as an extra bonus the kids can sleigh ride on it when they're home from school on snow days.  Dry the production shell the same way you dried the master shell.

Now you have made a production mold from start to finish by using the blanket mold system.  Well actually I have made a blanket mold from start to finish.  You on the other hand  are still reading this article.  But when you do tackle it I'm positive your performance will  be a five star, Oscar winning, Academy raving success.  When you make your acceptance speech don't forget all the little people who helped  you along the way.

Let's make another just like the other

To make duplicate molds fetch up the master shell from out of the root cellar or wherever you stuck it and give it a coat of wax and spray it with mold release.  Spray the model with release also as long as you're going around spraying things.  Clean up the side frame boards. Repair the fillets and place the master shell back in it's old home between the frame boards.  Make sure that everything that needs wax has been waxed and everything that needs mold release has been sprayed with it. 

 You do not have to make another clay blanket.  That part is over with for this job.  Hallelujah, hallelujah, yahoo,  praise be, thank the Lord. However you will have to follow the same clamping procedure, pouring, back up shell making and demolding as previously exhibited by your incomparable dexterity and execution of the principles presented forthwith. (  that means ya  gotta' do the same thing ya did last time 'ceptin for the clay part )

Congratulations!  You done good.   That was a real work out.  Now Let's get plastered!

Materials for this project are available by clicking the links on the left or visiting the Dan Does It !7 supplies page.

If you would like to have me make a mold for you  E-mail me. I'll be glad to discuss your project.

Other places to visit on our web site.  mold making services / sculpture tools / Dan Does It! Archives / Sculpture House / Deep Flex Molds / Foam carving tools / Rotational Casting Machines / Spray mold machines / Concrete jungle Molds / Artscape Concrete ornament  molds / Plaster info /