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Breakaway Glass Window Pane Sequence

There is a learning curve involved in getting good results with SMASH!® Plastic breakaway glass. The following tutorial takes you step-by-step through the process of making a large window pane suitable for using as a breakaway glass prop for stage or movie special effects.

You will need the following equipment:
  • Melamine Particle Board
  • Super Instant® Epoxy
  • Clear Acrylic Sheet (model)
  • Acrylic Strips (mold box)
  • Hot Glue Gun / Glue Sticks
  • Digital Gram Scale
  • Mold Max® 30 Silicone Rubber
  • Vacuum Degassing Chamber
  • SMASH! Plastic
 Remove protective coating on one side of the clear acrylic sheet

1 - Remove protective coating on one side of the clear acrylic sheet
 Adhere clear acrylic sheet to baseboard with super instant epoxy

2 - Adhere clear acrylic sheet to baseboard with super instant epoxy
 Place second board on top and apply pressure until epoxy cures

3 - Place second board on top and apply pressure until epoxy cures
 Make sure surface is level

4 - Make sure surface is level
 Hot glue base of retaining walls to prevent leaking

5 - Hot glue base of retaining walls to prevent leaking
 Measure and Mix Mold Max 30

6 - Measure and Mix Mold Max 30
 Construct retaining walls out of acrylic strips and hot glue

7 - Construct retaining walls out of acrylic strips and hot glue
 Vacuum Mold Max rubber for 2-3 minutes

8 - Vacuum Mold Max rubber for 2-3 minutes
 Remove protective coating from other side of clear acrylic sheet

9 - Remove protective coating from other side of clear acrylic sheet
 Pour Mold Max 30 in center of model

10 - Pour Mold Max 30 in center of model
 Rubber thickness should be 1/8” / 0.32cm. Let Rubber Cure 16 Hours at room temperature (72 F / 23 C)

11 - Rubber thickness should be 1/8” / 0.32cm. Let Rubber Cure 16 Hours at room temperature (72 F / 23 C)
 Peel away from model

12 - Peel away from model
 Place mold in oven/hotbox for 4 hours at 150F 60C

13 - Place mold in oven/hotbox for 4 hours at 150F 60C
 Place paper down the length of the mold. Purpose: Helps in demolding glass pane

14 - Place paper down the length of the mold. Purpose: Helps in demolding glass pane
 Place mold on paper

15 - Place mold on paper
 Safety: wear safety glasses and NIOSH approved respirator

16 - Safety: wear safety glasses and NIOSH approved respirator
 Mix ratio is 1A: 1B by weight or volume

17 - Mix ratio is 1A: 1B by weight or volume
 Dispense equal amounts of parts A and B into measuring containers

18 - Dispense equal amounts of parts A and B into measuring containers
 Pour Part A into mixing container

19 - Pour Part A into mixing container
 Pour Part B into mixing container

20 - Pour Part B into mixing container
 Mix thoroughly for 90 seconds

21 - Mix thoroughly for 90 seconds
 Pour SMASH! plastic into center of mold

22 - Pour SMASH! plastic into center of mold
 Slowly pull paper and mold off table edge while pane is secured

23 - Slowly pull paper and mold off table edge while pane is secured
 READY TO SMASH!

24 - READY TO SMASH!


Making a Breakaway Glass Pane

Watch more video online at Youtube

                   
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