1 - A decorative Roman Shield used as a model for duplication.

2 - Hot glue is applied to the back of the shield to adhere it to the board.

3 - Shield is pressed down on board to firmly secure it for the mold making process.

4 - Ease Release 200 is chosen as a release for the Rebound 40 rubber that will be used in this demonstration.

5 - A light mist of Ease Release 200 is sprayed on all surfaces for easy release of the Rebound 40 later on when the mold is finished.

6 - Rebound 40® is measured out 1:1 by volume for first layer.

7 - The individual components of the rubber are combined in a clean container for mixing.

8 - Rubber is double mixed in another container to ensure a proper consistency.

9 - First layer of Rebound 40® is brushed onto the surface of the shield.

10 - All surfaces, including the board, are covered in a thin layer of rubber.

11 - Silc Pig® Blue is used for the second layer to distinct it from the first layer, this will make it easier to see areas that need to be covered.

12 - A small amount of the Silc Pig® is dispensed into the Rebound 40® and mixed in. A double mix into a new clean container is mimicked from the first layer.

13 - The Silc Pig® is thoroughly mixed in and the second layer is brushed over top the first layer.

14 - Thi-Vex® is used in the third layer to thicken the rubber prior to brushing.

15 - Thi-Vex® produces a very thick product for filling in undercuts and potential weak areas.

16 - The thickened rubber is brushed in where the shield meets the board in order to make a tough strong edge.

17 - A last, colored and unthickened layer of Rebound 40® is applied to the shield mold to even out all surfaces.

18 - Rebound 40® mold is allowed to fully cure for 6 hours.

19 - Once cured, a straight edge and utility knife is used to clean up the edges of the rubber.

20 - Rubber flashing peels away from the board easily.

21 - Finished Rebound 40® mold ready for the support shell.

22 - Sonite® wax is chosen as the product to seal all surfaces prior to the application of the support shell.

23 - All surfaces, board and rubber, are covered with Sonite Wax.

24 - Two coats of Universal Mold Release® are applied to all surfaces to allow the cured support shell to be removed easily.

25 - Free Form® Molding putty is chosen as a lightweight and strong mother mold material.

26 - Free Form® is a lightweight putty that is easily dispensed by hand.

27 - Two equal sized portions of Free Form® are dispensed for easy 1:1 mixing of the product.

28 - Free Form® is hand mixed together.

29 - Mixing is complete when a uniform color has been achieved.

30 - A rolling pin, board, and wax paper will be used to roll out the putty into an even thickness.

31 - A sheet of wax paper is placed over the board and the Free Form® putty is pressed into the wax paper.

32 - A second layer of wax paper is placed over top the Free Form® putty and then a rolling pin smooths out the putty to the thickness of the guides on the board.

33 - The top layer of wax paper is removed to reveal a smoothed out layer of putty that is now the desired thickness (3/8'') for the support shell.

34 - Putty, while still on wax paper is positioned over the mold, ready to be pressed into place.

35 - Putty is placed in place and the wax paper is peeled back, leaving the putty on the mold.

36 - This method is repeated over the entire model, covering all surfaces.

37 - Excess putty can be trimmed with a wooden stick while it is still uncured thus eliminating any waste and making for little post-clean up work.

38 - Wax paper can be applied to the entire mold and the putty can again be rolled thus eliminating seems and making a nice uniform mother mold.

39 - The completed mold seem-free and ready for the next step.

40 - Plastic cups are positioned onto the putty in order to judge leg placement for the mold support.

41 - The impressions left from the cups mark where the legs will be placed on the mold.

42 - More putty is mixed and each cup is filled with the mixed putty.

43 - Cups are slightly overfilled to allow for ease of leveling out the final base.

44 - Cups are placed back onto the mold where the impressions were made.

45 - All four cups are now in the proper position.

46 - A level is used to make sure that the mold will sit solid once it is cured.

47 - All cups aligned perfectly thanks to the extra putty placed in each cup, which allowed for adjustment.

48 - Free Form® is allowed to fully cure overnight.

49 - In the morning, the mother mold is pried from the base board.

50 - The Free Form® shell is removed easily from the Rebound 40® mold.

51 - The Rebound 40® is peeled away from the master.

52 - The Free Form® mother mold is sanded smooth and the Rebound 40® fit back in, producing a perfect mold that captures all the detail of the original.

53 - The mold is now ready for casting Free Form® into it.

54 - Two coats of Ease Release 200® are applied to the molding surface.

55 - Wax paper is laid over top the rolling pin board in preparation of the Free Form®.

56 - Free Form® Putty is dispensed in equal amounts for the first layer of the casting.

57 - Once again, Free From® is mixed to a consistent color, placed on the board with a layer of wax paper placed over top and rolled out to a even thickness.

58 - Top layer of wax paper is pulled off revealing an evenly rolled out layer of Free Form® ready to be applied to the molding surface.

59 - The first layer of Free Form® is positioned and placed into the molding surface.

60 - The putty is then pressed into all the detail on the surface of the mold.

61 - The wax paper is removed from the Free Form®.

62 - Additional pieces of Free Form® are applied like the first piece.

63 - Each piece is carefully applied to the mold surface slightly overlapping a neighboring piece.

64 - Care is given to making sure seems are tightly pressed in, when applying additional pieces adjacent to each other.

65 - All sections of the molding surface is covered with Free Form® and all seams properly blended together.

66 - Casting is allowed to fully cure overnight.

67 - The next day, the Rebound 40® mold with the cured casting is removed from the mother mold.

68 - The Rebound 40® is easily peeled back off of the casting.

69 - The finished casting reflects perfect detail, is light weight and strong!

70 - Post Finishing - Free Form® is easily painted with acrylic paints.