Pour and Cure

After determining the volume of the bounding box, I calculated the required amounts of both parts of the mold solution to mix for my mold. A few minutes of vigorous mixing later, I had a solution that was ready to be degassed. 

We placed the solution in the vacuum to properly evacuate any lurking air bubbles in the solution. This took a couple passes but eventually the gas seemed to have been mostly gone from the mold mixture. 

After the solution was properly degassed, I carefully poured the mix into my foam-core/clay model, checking for leaks or spills and limiting the amount of air bubbles that popped up. 

Since the mold had a 40 minute cure time, it was time to leave and let the solution work its magic! 

~2 days later~

After a couple days, we came back and cracked open the foam-core box to see our first mold part. After clearing away the clay and some silicone residue, this is what we were left with.

After checking out the mold, I cut up some more foam-core to construct the second box with which the second part of the mold would be made. 

Once the new half of the box was filled with silicone, it was time to leave the remainder of the mold to set.

~A few days later~

After cracking the giant silicone block open, we now have a bright shiny new mold!