With the components to be molded ready for process, I began with the blade blank and hardware molds. Iâm not going to go into too deep of a description of the process on these parts. I employed a simple technique to execute these molds: build a little/big box close to the size of the parts to be molded, seal the box, affix the parts within the box using non-sulfuric clay, and pour the silicone. I will show photos of the molds when I get to the pulling casts stage.
For the main bodies of the prop I am employing a mix of techniques, a combination two-part & jacket/mother mold. I embedded the piece part way in clay on a nice flat piece of 1/4" (7ga) aluminum leaving 3/4 to 1" of overage to allow for the keys on the edge of the mold. This I hemmed with a small roll of clay to minimize spillage and allow for a thicker edge without much trimming. I used small (3/8") metal studs for keys. They are a nice shape and have two prongs on the bottom that help hold them in place. Here is a close photo of one half all âclayed upâ and ready for molding.






















, how much?