Allen Key Grip Mold and Casting

After I shaped my grip in clay the next step was to create the mold that I would use to cast multiple copies of my grip with resin. I decided to make my mold in two parts. I first made a box out of foam core and placed my grip into it. I had to make sure that the box allowed for at least 3/4" on all sides of my grip in all directions. I then filled the box with clay up to the top surface along the contour of my clay grip. I then poured silicon into the box and allowed it to dry. I did the same thing with the other side of the grip. After doing this process twice, I ended up with two silicon molds that fit against each other perfectly.

However, when I pulled out my clay grip from the mold I broke it. This wasn't a big deal but kind of disappointing.

The next step was to cut a hole in the top of the silicon box to be the entry point for the resin. I placed a small plastic funnel in the hole, wrapped the box in rubber bands to keep the two halves together, and then I was ready to prepare the resin.

The two liquids that I used to make the resin solution was a 1 to 1 ratio because I measured by volume. I used red dye for my first cast. I estimate the perfect amount. Almost zero waste!

My cast came out very nicely!

The next thing to do was to file it down. I thought taking it to the sandblaster would be a good idea.

This didn't turn out so well because the sand penetrated the surface of the cast and created little holes everywhere. For the next two casts, I decided to use a file and a dremmel instead.

I was very pleased with my three parts and had a great time doing this project.