In the first step we are going to make a plaster mold. Here's what you need to do.
Materials needed:
- 6” x 6” x 2” block of clay
- Clay tools
- 6” square picture of drawing (you can freehand this)
- Four pieces of scrap lumber 2” x 4” measuring 8 inches in length
- Hammer
- Nails
- Plastic bag
- Plaster
Lay your scrap lumber out to form a six-inch square. Hammer the board into place by overlapping them on the ends and nail at least two nails into each end.
You should now have an inside measurement of six inches square. Line this area by laying the plastic bag flat and pressing it into place. Make sure it comes up and over the sides. If you don’t cut open the plastic bag you will have a double sheet of plastic to help protect your surface and contain the plaster.
The next step you can do one of two ways. You can create your design on the clay and then transfer it into the two by four frame. This works but expect to do some touch up. The second method is to put the clay into the two by four mold now prior to creating your design. This way nothing will get shifted but you have the wood sides as obstacles on occasion. Either option works.
We are going to put the clay directly into the mold first. Prior to filling the mold, thoroughly knead the clay. When it has been kneaded, push it into the frame and even it up as much as possible before you begin. You don't want any air bubbles. Now you can either draw a design lightly on the surface or using a picture to impress a design through the paper onto the surface of the clay. Make sure to do this lightly as you will be altering it as you go.
Now you need to decide what areas will be raised and which areas will be sunken. Using your tools, remove the clay that is in the sunken areas making sure not to go all the way down to the plastic. Round or smooth the areas that are staying raised. Be careful not to go sideways, as this will cause problems. For example if you are carving out a face, you will want to put the nose but do not make deep nostrils. You will only want the suggestion of nostrils. You will appreciate this later.
Mix up the plaster as the direction state. Pour over your casting and allow to set up. It may only take an hour but you are better to allow it to cure over night to give the plaster the added strength before you disturb it.
When it is all set, remove the boards and plastic bags. Flip the whole piece upside down and you will have the clay on top and plaster on the bottom. Gently begin peeling away the clay. You can clean the mold with a Q-tip or very soft toothbrush but it is fragile. Now you are ready to cast. Stay tuned for our casting project.
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