Casting Cones

As I documented in a previous post, my first experience with casting was not entirely successful. But I did definitely learn a lot- and enough to embark on a smaller, simpler molding task as part of my performance prep for NW Congress last month.

Back in April 2012 I was preparing to show performance at NW Expo. I needed a single cone in two different performance set ups, one in Stablemate scale and one for a Schleich. I sculpted the two cones out of epoxy, and spent way too much time getting the base to be flat and square, and the cone to be… cone-shaped.

In progress cones

In progress cones

For NW Congress I needed at least four stablemate cones. But I didn’t have the time (or patience) to sculpt four more. Plus, I knew it would bug me if they didn’t match. But since the cone has one flat side, I realized that I could do a one-part mold and cast a few more relatively easily.

One part molds are simpler because you only have to pour rubber once, and you don’t have to worry about two parts fitting together perfectly. It’s also easier to pour the liquid plastic.

To make the mold, I took a little plastic cup (like what you’d eat yogurt or fruit out of) and lightly glued the original epoxy cone to the bottom, pushing it down so it was flush with the bottom. I didn’t want the cone to move around when I poured the rubber, and any little imperfection caused by a glue lump would be easily correctable by sanding (it ended up not being an issue at all).

making cone mold

I waited for the glue to set and so that the cone was firmly affixed to the cup. Then I mixed up my liquid rubber and poured it into the cup, making sure to cover the whole height of the cone. After it set, I had a nice little cone mold:

cone mold

Once the mold was done I poured my liquid plastic into it. I thought it might be hard to get it exactly full, but the flat base of the cone made it pretty easy. I recommend pouring from something that you can squeeze to make a kind of spout to control the pour. Handily, any little extra plastic that left on the top was only a very thin layer, so it’s easy to remove after the plastic sets.

I poured four cones, and with a bit of sanding and paint I had a lovely set:

set of cones

On the left is the original epoxy cone, and one the right are my four plastic copies.

The cones are great. I used them in a bunch of my performance set-ups at NW Congress, and I certainly will use them many more times. And if I need more, it’s not hard to make some!

cones in english games

I used the cones in English Games to mark the finish line in Red Light Green Light .

Cones are amazing useful for performance showers- almost essential, really. In fact, while I was working on this post, Jennifer Buxton wrote a post on her blog all about using cones in performance. She also mentions a great (and inexpensive) resource for buying Traditional sized cones. And as usual, a bunch of fun pictures too :)

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