This Chistmas vacation I decided to finally get out that Alumilite casting kit my wife got me two Christmases ago. The contents had (quite) settled in that time, but were still usable. I’d never made molds or cast anything in my life, so naturally not knowing what I was doing, I winged it.
The rubber mold process threw me a bit. Opening the lid and pouring a bit, I was greeted by a clear, thick fluid resembling snot. Being ignorant of these things, I assumed that was my molding rubber, and mixed some up per the instructions. The intent was to replicate windows and tiny detail parts that make my hands want to fall off. Long ago I had started building Hope station, but had given up because the process of making the windows and mullions (that is what those window sticks are called) was just too laborious and finicky. Now I could make one good window, or one good door, and cast hundreds of them.
What I did not realize of course was that the clear fluid pouring out of the RTV silicone can was one part of what was supposed to be a mixture. At the base of the can was a white compound that was supposed to be mixed with the clear stuff but, after years of sitting, had separated. Before I realized what was going on and found myself with a tub of hard white goo in the bottom of the can, I had run out of the clear stuff and could not remix. Lucky for me, the clear stuff provided ideal molds anyway for my tiny detail parts. I then mixed up the Alumilite Part A and Part B plastic mix, stirred it up nice, and did a pour. Way too much for my tiny mold, and I ended up with a half cup of solid plastic after. Eventually I ended up mixing it in a pen cap. Just a few drops at a time of each part. After a few test casts, I had enough confidence to fire off a few windows and doors and soon Hope station, the project, was recovered and on its way.
A note about casting though – it takes patience, and care. After making a bunch of windows I decided to create a mold of a few of them so I could cast a bunch at once, which worked fine *except* I found the more alumilite I mixed up, the more difficult it was to pour and avoid bubbles, and the quicker it set. I eventually just went back to mixing tiny amounts – 8 drops each of Part A and Part B. Got it down to a science!
Pictured is the still unassembled Hope station, with fancy (and in need of sanding and finishing) new windows!