Plaster casting help needed

Hi all, sorry about the cross-posts, but they're germaine to the subject matter...

I'd like to make a catacombs for a haunted house. I want to cast a skull (face) about 6-800 times. What's the best way to make a mold to pour plaster into?

Any help at all would my most helpful...

You can post here or e-mail me-

thanks and again sorry for the cross post

I have a skull mold, one-piece, makes a solid-plaster skull, always does well at Halloween. For that quantity you need a bunch of molds or a gang mold so you don't mix hundreds of times. Contact me directly if interested.

Kin, if I was undertaking this project, I would make a case pour mold.

You don't give any extra details. Is the skull (face) 'life' size??

Are you wanting to cast full skulls with, or without the lower jaw, moveable jaw, or locked??

Or, just a low relief face??

Assuming a full skull, jaw locked in place:

Fix your model to a suitably sized table, and prepare it for a polyurethane mold.

I would use the SmoothOn Evergreen 20.

Clay over your model with about one half inch of clay, covering the model with a plastic bag first.

Now you can produce a pouring case.

Remove the pour case. Remove the clay. Apply release agent. Put the pour case back in place.

Pour the polyurethane into the case. Remove the pouring case when the rubber is fully cured. Leaving the rubber mold in place on the model.

Now make a case for your first mold. Remove this case, and the first mold, leaving the model fixed on the table.

You can now begin casting into the first mold.

Release agent again on the model if needed. Put the pour case back in place.

Pour rubber in this case for the second time. Remove the pouring case when the rubber is fully cured.

Now make a case for your second mold. Remove this case, and the second mold, leaving the model fixed on the table.

Now you have two molds to cast into. I would repeat this until I had a dozen molds, or more, depending on how much time you have to devote to casting these 800 pieces. If you have plenty of time, make one mold, and pour them one at a time. 800 times 30 minutes equals ten forty hour weeks. 12 molds at a time could be done in less than a week (casting time).

Or, a moldmaker can provide the mold(s) for you. I have three different skulls available, with or without the lower jaw. Mine are taken from actual human skulls, with all of the thirty two teeth intact.

Post back, and let us know how your project comes out, and, I would like a copy of a photo of the eight hundred skulls all lined up like ducks in a row.

Good luck,

Thanks people.... the hints are MUCH appreciated.