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Making
the plaster production mould, Page Two of Three.
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This
shows the set-up just before pouring the Port big side. It is difficult
to judge the scale from a photo, but the distance from top to base
is nearly 18 inches, and the same from front to rear. The average
depth is 3 inches. This is about half a cubic foot and the part
weighed nearly 25 pounds of water and plaster.
The best instruction book on handling plaster I have come across
is "Mold Making for Ceramics" by Donald E. Frith, ISBN
- 0-8019-7359-7. He covers the history of molds, plaster and slip-making
but not making multi-part moulds.
He warns of accidents if the set-up is not properly secured against
the pressure of this weight of mixed plaster. In addition to wood
screws at the corners, I tied the top board to the baseboard with
nylon luggage straps, with two more around the circumference.
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This
shows the set-up for the starboard big side. All the natches are
cut into the internal segments. These will locate them into the
starboard big side. A little bit of the previous plaster casting
of the port big side can be seen above the spine, with the natches
as positives, sticking up. This area is the only bit where the two
big sides touch. In this way, I hoped that any expansion would be
upwards, towards the surface, and not force the existing segments
apart.
I have
marked with pink lines the keystone wedge. The sides of this wedge
where it touches adjacent segments should be smooth, so that when
the big sides are taken off, the wedge slides out. Then the inner
front leg segment can be removed and then the inner back leg segment.
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The next
page shows the segments separated from the mould.
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