I used to cast all our Rock from plaster until we had slight problem with a section on benchwork. It cracked the main facia boards from flexing. So I ended up switching over to a more forgiving material and could still use the same molds.
Expanding Urethane Insulation Foam, the type used to seal gaps around your home. http://greatstuff.dow.com/products/gaps-and-cracks/
It is so easy and lightweight it was not funny. And since the mold surface dictates the "skin" side of the casting the detail is still there. Plus you can cut it with a razor knife. Priming and Painting is slightly different technique, but for large sections it really was easier to carry a 2 pound section that was 23" x 49" - Floor to Table section.
Just an idea for ya. Something that worked for us.Last edited on Sat May 14th, 2011 12:03 pm by Nn3Designs
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