Expandable spray foam, for example, can be carved into shapes much like any other foam. With the mold shaped and covered with tape, I rubbed on one coat of paste wax as a mold-release agent. The mold can be made out of foam, mdf or other stable and shapeable materials. The sanded and trimmed part being fit in place. Whenever dealing with mold removal, always wear proper safety clothing. After a summer of sailing, the part and cleat have not moved. A male mold was the best choice for creating the shape to put the cleat where I wanted it. A variety of materials can be cast in a PlatSil 73-40 silicone mold, many of which don’t require a release agent. 18) As a last and experimental new step…I have cut away some foam onto my shoulder wires in the hopes that I can animate the puppet’s shoulders up and down. 9) Approximate how much foam you need keeping in mind that the foam will expand to 10 x its size. Let’s look at some of the materials you can use, as well as a ‘how-to’ guide to building your own reusable mold for foam casting. 5) Brush vaseline everywhere in the mold. 16) When you open the mold you will see that there is extra foam outside of the main mold shape (this is called flashing). For irregular shapes you can make your own sanding/shaping tools by spray gluing sand paper to your specially shaped backer board, high density foam can also be used for this. To make the foam less ugly you can do many things. (The spoon was just a quick way to tighten the rubber band haha). The part I made had to be strong enough to withstand the loads of the traveler. I didn’t mind if the tape overlapped because this would be inside of the finished part and not visible. Can be coloured with small amount of acrylic or oil paint mixed in (unbelievably, oil paint doesn’t affect it). On one cup, mark a line with a sharpie for ½ the amount of foam you want to pour. Anyhow, I used three cases of 750ml containers to fill-in the would be female mould. 15) You can remove the foam after 30 minutes or so, if you are nervous about this you can check the leftover foam in the cup  to see if it has cured and solidified. This post will explain how to cast expandable foam around wire armatures in plaster molds. Frank and Norm go over the moldmaking process and show how self-skinning expanding foam can make great-looking stunt props for your projects. We go over the moldmaking process and show how self-skinning expanding foam can make great-looking stunt props for your projects. The denser the material, the more it will hold up over multiple pressings, but the harder it will be to shape. Oct 27, 2017 - Explore Kelli Hudson's board "Spray Foam Crafts", followed by 118 people on Pinterest. Pour water up to this mark then pour the water into a second cup. "Submitted by Ace Monster Toys for the Instructables Sponsorship Program" Spray 2 coats and wait 5 minutes between each coat. Do not use puppet for 6 hours. This includes polyester, epoxy, wax, concrete, plaster, and polyurethane resins and foams. This step can be adequately done in an hour or half.Step 2: Once you’re satisfied with the shaping and final outline, you can wrap up the plug with a layer of packing tape to stop the epoxy from seeping into the foam. I wish I had done this a year or two earlier. I faired the part then coated the surface with WEST SYSTEM 105 Resin and 205 Fast Hardener tinted with 501 White Pigment. Thanks to the paste wax, the part came off the mold easily. It was my personal choice to include the neck and forearms in the plaster mold (resulting in extra foam to cut away/waste of materials) just because I had trouble visualizing how to cut it into pieces that would fit together. Stop mold before it starts by keeping moisture out of your home the part. 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