Outcome

The first step in the process was to create the mold. To do that, a box was built around the clay part with a one inch distance from the part. Once the box was created, white clay was packed all around the part up to about half its height. This was done to create the first side of the mold. 

Once that is done, a silicon mixture is poured on top of the part and the white clay to create a mold of side that is exposed. 

The picture above shows the mold after the first side was molded. The bumps around the edges of the mold are used to line up the mold correctly once both sides are finished. The walls are rebuilt around the half mold, and then the other side of the mold is made by pouring the silicon mixture.

Once the other side is finished, the mold is split in half and the mold is ready to be used for casting. 

Once the mold is ready, it is wrapped in rubber bands to ensure that the mold is tightly pressed together. Then, a funnel is inserted at the top, and another mixture is poured through the funnel. The mixture induces an exothermic reaction, and in about 6 hours mixture becomes fully cured and the part has been made.

Once the mold cures for 6 hours, the mold is split open and the part is there. The part is then taken out of the mold, and all the excess material on the edges is sanded off. 

From the pictures above, it is apparent that the finish is not very smooth from the mold. Because of this, a dremel was used with a sanding head to smooth the piece down.

After a few hours of sanding, the final product came out as pictured above. The cast was redone two other times, and the results can be seen below along with the clay part used to create the mold.