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Replacing a Brass Shower Door Handle at a Fraction of the Cost
The original brass shower door handle, over time, cracked and broke.  The homeowner contacted the door manufacturer for a new one and was informed that the handle was discontinued, however a custom replacement could be purchased from another company.  The cost of the replacement handle was substantial. A replacement "Cold Cast Brass" handle could be molded and cast with Oomoo® 30 silicone rubber, Task® 9 performance casting resin and Brass Metal Powder  for a fraction of that cost.
 The original brass handle, over time, cracked and broke.

1 - The original brass handle, over time, cracked and broke.
 Broken brass shower door handle.

2 - Broken brass shower door handle.
 A sister handle is removed from another door to use in making the mold.

3 - A sister handle is removed from another door to use in making the mold.
 Gather all supplies needed before you start.

4 - Gather all supplies needed before you start.
 A plastic deli cup is cut to size for the mold container.

5 - A plastic deli cup is cut to size for the mold container.
 Aluminum foil will be used as a base for the mold container.

6 - Aluminum foil will be used as a base for the mold container.
 The good handle is hot glued to the aluminum foil by applying a bead of glue around the outside edge.

7 - The good handle is hot glued to the aluminum foil by applying a bead of glue around the outside edge.
 The handle is firmly pressed onto the center of the aluminum sheet..

8 - The handle is firmly pressed onto the center of the aluminum sheet..
 The deli cup is centered around the handle and glued down.  The mold container must have 1/2 inch clearance on all sides, including the top.

9 - The deli cup is centered around the handle and glued down. The mold container must have 1/2 inch clearance on all sides, including the top.
 Safety First. Wear vinyl gloves when working with these materials.

10 - Safety First. Wear vinyl gloves when working with these materials.
 Read the Technical Bulletin before using these products.

11 - Read the Technical Bulletin before using these products.
 Shake Well before using.

12 - Shake Well before using.
 Carefully measure required amount of Oomoo® 30 Part A.

13 - Carefully measure required amount of Oomoo® 30 Part A.
 Measure out and equal amount of Oomoo® 30 Part B.

14 - Measure out and equal amount of Oomoo® 30 Part B.
 Combine Part A and B into a mixing container.

15 - Combine Part A and B into a mixing container.
 Mix thoroughly until a uniform color is achieved and no color streaks are visible.  Scrape sides and bottom of the container to ensure a good mix.

16 - Mix thoroughly until a uniform color is achieved and no color streaks are visible. Scrape sides and bottom of the container to ensure a good mix.
 When no color streaks are visible, transfer mixture to a 2nd clean mixing container.

17 - When no color streaks are visible, transfer mixture to a 2nd clean mixing container.
 Mix thoroughly for an additional 1 minute.  Make sure no color streaks are visible.

18 - Mix thoroughly for an additional 1 minute. Make sure no color streaks are visible.
 Slowly pour silicone around the handle.

19 - Slowly pour silicone around the handle.
 Liquid silicone should completely cover the handle by 1/2 inch over highest point.

20 - Liquid silicone should completely cover the handle by 1/2 inch over highest point.
 Oomoo® 30 requires a minimum of 6 hours to cure.

21 - Oomoo® 30 requires a minimum of 6 hours to cure.
 Once the Oomoo® 30 is cured, remove the aluminum foil from the base.

22 - Once the Oomoo® 30 is cured, remove the aluminum foil from the base.
 Gently remove the mold from the container.

23 - Gently remove the mold from the container.
 Gently remove the handle from the mold.

24 - Gently remove the handle from the mold.
 Oomoo® 30 silicone mold rubber captured perfect detail and is ready for casting.

25 - Oomoo® 30 silicone mold rubber captured perfect detail and is ready for casting.
 Gather all materials needed to make the casting before you start.

26 - Gather all materials needed to make the casting before you start.
 A measuring line is marked on a small cup.  Very little material will be required to make this casting.

27 - A measuring line is marked on a small cup. Very little material will be required to make this casting.
 Brass Metal Powder is measured to the line.

28 - Brass Metal Powder is measured to the line.
 The Brass Metal Powder is dispensed into the mixing cup.

29 - The Brass Metal Powder is dispensed into the mixing cup.
 Using the same measuring cup, carefully measure Task® 9 resin Part B to the line.

30 - Using the same measuring cup, carefully measure Task® 9 resin Part B to the line.
 Pour Task® 9, Part B into the mixing cup containing the Brass Powder.

31 - Pour Task® 9, Part B into the mixing cup containing the Brass Powder.
 Thoroughly mix the Part B with the Brass Powder continually scraping the sides and bottom of the cup while mixing.

32 - Thoroughly mix the Part B with the Brass Powder continually scraping the sides and bottom of the cup while mixing.
 Carefully measure Task® 9, Part A.

33 - Carefully measure Task® 9, Part A.
 Pour Part A into the mixing cup containing the Brass Powder and Part B.

34 - Pour Part A into the mixing cup containing the Brass Powder and Part B.
 Mix thoroughly scraping the sides and bottom of the container several times.

35 - Mix thoroughly scraping the sides and bottom of the container several times.
 Slowly pour the liquid mixture into the mold cavity until completely full.

36 - Slowly pour the liquid mixture into the mold cavity until completely full.
 Allow the resin to cure a minimum of 60 minutes before demolding.

37 - Allow the resin to cure a minimum of 60 minutes before demolding.
 A drill is used to carefully clean out the screw holes.

38 - A drill is used to carefully clean out the screw holes.
 Steel wool is used to polish the cast replacement handle.

39 - Steel wool is used to polish the cast replacement handle.
 The handle is attached to the shower door.

40 - The handle is attached to the shower door.
 The new handle perfectly matches the shower door trim.

41 - The new handle perfectly matches the shower door trim.

                   
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