Then there is grandmother’s 19th-century bureau. Our bureau was in perfectly good condition except for some missing knobs. Well, we were now confident we could fix that using the identical methods described in the previous posting. Except, instead of using brass powder, we will use ground pecan shell powder and KastEZ resin to match the color of the wood.
We unscrewed a knob from the bureau and hot-glued it to the bottom of a small container. We then mixed up some MoldRite 25, 2-part silicone, and covered the knob to a height of about 1/2 inch above its highest point. We then vibrated it to rid it of air bubbles.
When the mold rubber set, we sliced the mold open using a saw-toothed pattern to remove the original knob and baked the mold to season it. At the same time, we baked some pecan shell powder in the oven to rid it of moisture. The instructions suggest baking for about 3 hours at 150-200°F.
Mahogany or Oak?
Casting wood requires a bit more finesse than casting other materials as wood colors vary a great deal. However, EnvironMold points out that a serviceable look of oak or mahogany can be achieved by substituting the resin. Using AquaClear resin and pecan shell flour will result in a mahogany wood tone.
Using KastEZ resin by itself sets to an ivory tone, but with pecan shell powder, you can achieve a satisfactory oak or maple tone. We did both even though our bureau was a maple veneer.
Casting the Wooden Knob
When the mold is ready, follow the procedure you used to cast the brass knob. Measure out equal parts of Part A and Part B of KastEZ or AquaClear resin, and an equal part of pecan shell powder. The formula is 1/3 flour, 1/3 Part A, and 1/3 Part B.
We premixed the flour by dividing the pecan shell powder in half, between Part A and Part B. Then we mixed one half in Part A and one half in Part B in the KastEZ resin. After mixing thoroughly, we then added both mixtures together and continued mixing. It doesn’t matter which part we poured into the other. After mixing all the material for about 45 seconds to one minute, we poured it into the wood knob mold and vibrated it. We waited about three hours before demolding.
After removing the finished knob from the mold, we cleaned up the flashing and polished it with 000 steel wool to remove the resin and expose the wood. We could have stained or painted the knob to better match an original. However, with several coats, we achieved an excellent copy just as promised.
The original and two copies of a wooden bureau knob along with the silicone mold. One copy was created using KastEZ resin for the oak finish, the other with AquaClear resin for a mahogany look.
Molding and Casting Materials Used
Here are the mold-making and casting products utilized in the duplication of the hardware in this article. With them, you can reproduce a wide variety of objects in a technique called cold casting in bonded metals of all types, simulated glass, marble, and even wood.
MoldRite25 Silicone. It contains everything you need to make an easy-to-release rubber mold.
KastEZ Resin. It is an opaque white resin used to simulate ivory, porcelain, and bonded wood.
EnvironMolds offers 5 high-quality and very fine ground 325-screen mesh casting media. This includes copper, brass, bronze, marble, and wood powders to create cold casting which duplicates the original. By mixing 1/3rd by volume of any of the casting media with 1/3 Part A and 1/3 Part B of either AquaClear or KastEZ resin, a simulated hot foundry metal or other material may be achieved.
Last Words
In conclusion, mastering the art of mold making and casting opens up endless possibilities for creating detailed, high-quality replicas and custom parts. Whether you are a seasoned professional or a passionate hobbyist, the right materials and techniques are crucial for achieving the best results. At EnvironMolds, we take pride in offering an exceptional line of ArtMolds mold-making and casting materials designed to meet the diverse needs of our customers. From silicone and resin to metal casting supplies, our products are engineered to provide precision, durability, and ease of use. Explore our extensive range and discover how you can elevate your projects with the finest materials available. Thank you for joining us on this journey through the fascinating world of mold making and casting. Happy crafting!
ED MCCORMICK
Edmund McCormick is the founder of Cape Crystal Brands and EnvironMolds LLC. He is the author of several non-fiction “How-to” books, past publisher of the ArtMolds Journal Magazine, editor of Beginner's Guide to Hydrocolloids, and author of six eBook recipe books available for download on this site. He resides in Far Hill, NJ and lives and breathes his art and food blogs as both writer and editor. You can follow him on Twitter and Linkedin.
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