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Replacing a Hard To Find 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.
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1 - The original brass handle, over time, cracked and broke.
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2 - Broken brass shower door handle.
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3 - A sister handle is removed from another door to use in making the mold.
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4 - Gather all supplies needed before you start.
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5 - A plastic deli cup is cut to size for the mold container.
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6 - Aluminum foil will be used as a base for the mold container.
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7 - The good handle is hot glued to the aluminum foil by applying a bead of glue around the outside edge.
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8 - The handle is firmly pressed onto the center of the aluminum sheet..
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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.
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10 - Safety First. Wear vinyl gloves when working with these materials.
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11 - Read the Technical Bulletin before using these products.
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12 - Shake Well before using.
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13 - Carefully measure required amount of Oomoo® 30 Part A.
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14 - Measure out and equal amount of Oomoo® 30 Part B.
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15 - Combine Part A and B into a mixing container.
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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.
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17 - When no color streaks are visible, transfer mixture to a 2nd clean mixing container.
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18 - Mix thoroughly for an additional 1 minute. Make sure no color streaks are visible.
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19 - Slowly pour silicone around the handle.
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20 - Liquid silicone should completely cover the handle by 1/2 inch over highest point.
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21 - Oomoo® 30 requires a minimum of 6 hours to cure.
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22 - Once the Oomoo® 30 is cured, remove the aluminum foil from the base.
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23 - Gently remove the mold from the container.
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24 - Gently remove the handle from the mold.
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25 - Oomoo® 30 silicone mold rubber captured perfect detail and is ready for casting.
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26 - Gather all materials needed to make the casting before you start.
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27 - A measuring line is marked on a small cup. Very little material will be required to make this casting.
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28 - Brass Metal Powder is measured to the line.
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29 - The Brass Metal Powder is dispensed into the mixing cup.
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30 - Using the same measuring cup, carefully measure Task® 9 resin Part B to the line.
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31 - Pour Task® 9, Part B into the mixing cup containing the Brass Powder.
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32 - Thoroughly mix the Part B with the Brass Powder continually scraping the sides and bottom of the cup while mixing.
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33 - Carefully measure Task® 9, Part A.
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34 - Pour Part A into the mixing cup containing the Brass Powder and Part B.
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35 - Mix thoroughly scraping the sides and bottom of the container several times.
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36 - Slowly pour the liquid mixture into the mold cavity until completely full.
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37 - Allow the resin to cure a minimum of 60 minutes before demolding.
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38 - A drill is used to carefully clean out the screw holes.
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39 - Steel wool is used to polish the cast replacement handle.
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40 - The handle is attached to the shower door.
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41 - The new handle perfectly matches the shower door trim.

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