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I have a fish I carved from HDU that is a logo for a restaurant. It's about 15" x 12". I need to make several more and I'm thinking of casting them. I know how to make a latex mold, but I'd like to find a material that's outdoor durable, but non-toxic to work with. I can't use resin and hardener like I used to use on surfboards, I can't take the fumes. Concrete could work but its heavy and brittle. Plaster isn't good outdoors. Does anyone know of some type of foam similat to HDU in consistency that isn't a two part system with a strong odor? Thanks in advance.
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Chuck, you might consider lightweight concrete like they use to pour second story balconies and such. Not sure exactly what they use for an aggregate, but it's something like pumice or vermiculite, and it weighs about half of what regular concrete does. A concrete contractor should be able to steer you in the right direction.
------------------ Jerry Mathel Jerry Mathel Signs Grants Pass, Oregon signs@grantspass.com
Posts: 916 | From: Grants Pass, OR USA | Registered: Dec 1998
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You could use fiberglass reinforced concrete.
Lighter than regular concrete yet still strong thanks to the fibers in it.
Since yer gonna have to build a two piece mold to do that shape, you could build an inner form as well, to create a hollow interior in the concrete making it even lighter.
------------------ Mike Pipes Digital Illusion Custom Graphics Lake Havasu City, AZ http://www.stickerpimp.com
Posts: 8746 | From: Lake Havasu, AZ USA | Registered: Jun 2000
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You might want to check into some of the Smooth-On liquid plastics. They have dozens of different types and curing times. They are a two-part mix, but the fumes aren't that bad. You could do a slush cast and they wouldn't weigh much at all. I think the website is www.smooth-on.com Good luck.
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Chuck, I use a product called poly foam from polytech, their located in easton PA. www.polytech.com
It is a two part mix 1to1 ratio almost no odor and the part is light weight, can be carved and you can demold the part in minutes which means you can cast your duplicats in an hour or two.
Rich Litzenberger Dorney Park Allentown, PA rlitzenberger@dorneypark.com
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Posts: 31 | From: Allentown, PA, USA | Registered: Oct 2000
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If you phone Douglas & Sturgess in SF, and talk to Art, he can direct you and instruct you with the best stuff for your situation. http://www.artstuf.com/ They are a great source for casting supplies!
------------------ The SignShop Mendocino, California "Where the Redwoods meet the Surf"
Posts: 6805 | From: Mendocino, CA. USA | Registered: Nov 1998
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