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Recreating a 19th Century 
piece of American History

Rebound® 25 was used in molding a 19th century Long Rifle to make casts available for historical societies. Preservation of the original without altering the look or pantina was the major consideration when choosing the right materials for making the replicas.  Smooth-On's Rebound® 25 was chosen for it's ease of use and ability to release cleanly from the original model.
 19th century historical long rifle is going to be used to make museum-quality replicas of this important piece of American history.

1 - 19th century historical long rifle is going to be used to make museum-quality replicas of this important piece of American history.
 Sculptex®, a very malleable, low cost oil clay is used to make a dividing wall around the rifle.

2 - Sculptex®, a very malleable, low cost oil clay is used to make a dividing wall around the rifle.
 The clay is laid on either side of the rifle, bisecting it for making a two piece mold.

3 - The clay is laid on either side of the rifle, bisecting it for making a two piece mold.
 A foam plug was made out of ear plugs to be placed inside the barrel to keep silicone from flowing inside of it.

4 - A foam plug was made out of ear plugs to be placed inside the barrel to keep silicone from flowing inside of it.
 The foam plug will not damage the inside of the barrel and slightly expands to keep out the silicone.

5 - The foam plug will not damage the inside of the barrel and slightly expands to keep out the silicone.
 Small pieces of dowel are used for venting areas of the mold that could potentially trap air in the final casting.

6 - Small pieces of dowel are used for venting areas of the mold that could potentially trap air in the final casting.
 The dowel ''gate'' is placed at the highest tip of the hammer so air can escape back down the gun stock.

7 - The dowel ''gate'' is placed at the highest tip of the hammer so air can escape back down the gun stock.
 Keys are cut into the clay with a Popsicle stick in order to register the two silicone halves when cured.

8 - Keys are cut into the clay with a Popsicle stick in order to register the two silicone halves when cured.
 Rebound® 25 will be used as the mold making rubber.

9 - Rebound® 25 will be used as the mold making rubber.
 Rebound® is dispensed 1:1 by volume.

10 - Rebound® is dispensed 1:1 by volume.
 Rebound® is mixed in a clean mixing container to a even color consistency.

11 - Rebound® is mixed in a clean mixing container to a even color consistency.
 The Rebound® is brushed directly onto the rifle and clay bed.

12 - The Rebound® is brushed directly onto the rifle and clay bed.
 Once the entire gun is covered in a layer of Rebound®, it is allowed to set up prior to adding the second coat.

13 - Once the entire gun is covered in a layer of Rebound®, it is allowed to set up prior to adding the second coat.
 Thi-Vex® Silicone Thickener is used for subsequent layers to thicken the Rebound®.

14 - Thi-Vex® Silicone Thickener is used for subsequent layers to thicken the Rebound®.
 The Thi-Vex® added to the silicone makes the silicone thicker for building up key areas.

15 - The Thi-Vex® added to the silicone makes the silicone thicker for building up key areas.
 The thickened silicone is applied to the gun and flange.

16 - The thickened silicone is applied to the gun and flange.
 Ice cube trays are filled with Rebound® 25 in order to create keys that will help register a support shell onto the silicone correctly.

17 - Ice cube trays are filled with Rebound® 25 in order to create keys that will help register a support shell onto the silicone correctly.
 Two trays are filled partway to create these keys.

18 - Two trays are filled partway to create these keys.
 Once cured, the ice cube shaped keys are placed on a tacky layer of silicone covering the gun.

19 - Once cured, the ice cube shaped keys are placed on a tacky layer of silicone covering the gun.
 Additional silicone is used to cover the keys and secure them to the mold.

20 - Additional silicone is used to cover the keys and secure them to the mold.
 The final layer of silicone is applied without Thi-Vex® and smoothed out over the length of the mold.

21 - The final layer of silicone is applied without Thi-Vex® and smoothed out over the length of the mold.
 Once fully cured, a straight edge is used to cut the edges of the rubber in order to make a  nice clean mold.

22 - Once fully cured, a straight edge is used to cut the edges of the rubber in order to make a nice clean mold.
 The razor knife cuts easily into the rubber providing a nice clean edge.

23 - The razor knife cuts easily into the rubber providing a nice clean edge.
 The razor knife cuts easily into the rubber providing a nice clean edge.

24 - The razor knife cuts easily into the rubber providing a nice clean edge.
 The finished first side ready for the first half of the support shell.

25 - The finished first side ready for the first half of the support shell.
 Cardboard strips will be used as retaining walls for the application of the support shell.

26 - Cardboard strips will be used as retaining walls for the application of the support shell.
 The cardboard is hot glued around the gun model.

27 - The cardboard is hot glued around the gun model.
 Free Form® Air will be used for the support shell, chosen for its light weight and durability.

28 - Free Form® Air will be used for the support shell, chosen for its light weight and durability.
 Equal parts of Free Form® Air are measured out by volume.

29 - Equal parts of Free Form® Air are measured out by volume.
 Free Form® Air is mixed by hand.

30 - Free Form® Air is mixed by hand.
 A rolling pin and Clay Board covered in aluminum foil will be used to roll out even thicknesses of the Free Form® Air.

31 - A rolling pin and Clay Board covered in aluminum foil will be used to roll out even thicknesses of the Free Form® Air.
 The Free Form® Air is spread across the board.

32 - The Free Form® Air is spread across the board.
 Another layer of Aluminum foil is placed over the Free Form® Air then smoothed with the rolling pin.

33 - Another layer of Aluminum foil is placed over the Free Form® Air then smoothed with the rolling pin.
 The Aluminum foil peels easily away, revealing a nice, even layer of Free Form® Air.

34 - The Aluminum foil peels easily away, revealing a nice, even layer of Free Form® Air.
 The Free Form® Air is placed over top the Rebound® and the bottom piece of Aluminum foil is pulled away from the putty.

35 - The Free Form® Air is placed over top the Rebound® and the bottom piece of Aluminum foil is pulled away from the putty.
 The method is repeated until the whole mold is covered in a uniform layer of Free Form® Air.

36 - The method is repeated until the whole mold is covered in a uniform layer of Free Form® Air.
 A gloved hand dipped in water will be used to smooth down the Free Form® Air to make a smooth, clean support shell.

37 - A gloved hand dipped in water will be used to smooth down the Free Form® Air to make a smooth, clean support shell.
 The addition of water evens out the putty, producing a finished look.

38 - The addition of water evens out the putty, producing a finished look.
 Once, allowed to cure overnight, the cardboard walls are removed.

39 - Once, allowed to cure overnight, the cardboard walls are removed.
 Once the cardboard sides are removed, the model is lifted from the board in order to start the second half.

40 - Once the cardboard sides are removed, the model is lifted from the board in order to start the second half.
 The model is flipped over to expose the clay bed.

41 - The model is flipped over to expose the clay bed.
 The clay is removed from the model and Rebound®.

42 - The clay is removed from the model and Rebound®.
 All traces of clay are cleaned off in preparation of the second side of Rebound®.

43 - All traces of clay are cleaned off in preparation of the second side of Rebound®.
 Ease Release® 205 will be used on the cured Rebound® to prevent the new layer from bonding.  Ease Release® 205 was chosen so it can be carefully brushed on without affecting the gun.

44 - Ease Release® 205 will be used on the cured Rebound® to prevent the new layer from bonding. Ease Release® 205 was chosen so it can be carefully brushed on without affecting the gun.
 Using a brush makes application of the Ease Release® 205 easy.

45 - Using a brush makes application of the Ease Release® 205 easy.
 Rebound® is processed and applied in the same way it was on the first application of the mold.

46 - Rebound® is processed and applied in the same way it was on the first application of the mold.
 Rubber keys are once again placed on the curing Rebound® to help the mold rubber register inside the Free Form® Air shell.

47 - Rubber keys are once again placed on the curing Rebound® to help the mold rubber register inside the Free Form® Air shell.
 Once all the layers of Rebound® have been applied, the rubber is once again cut and the cardboard sides are reassembled around the model.

48 - Once all the layers of Rebound® have been applied, the rubber is once again cut and the cardboard sides are reassembled around the model.
 Ease Release® 200 (Although the Ease Release® 205 used previously could also be used) is used to make sure that the new application of Free Form® Air will not bond to the first layer of Free Form® Air when trying to separate the two halves.

49 - Ease Release® 200 (Although the Ease Release® 205 used previously could also be used) is used to make sure that the new application of Free Form® Air will not bond to the first layer of Free Form® Air when trying to separate the two halves.
 A liberal coat of Ease Release® 200 is sprayed onto all surfaces.

50 - A liberal coat of Ease Release® 200 is sprayed onto all surfaces.
 Free Form® Air is once again processed and laid on the second half of the mold rubber.

51 - Free Form® Air is once again processed and laid on the second half of the mold rubber.
 Once the second layer of Free Form® Air had an overnight cure, the sides are once again pulled off and the model is lifted off the board in order to open the mold.

52 - Once the second layer of Free Form® Air had an overnight cure, the sides are once again pulled off and the model is lifted off the board in order to open the mold.
 The first half of the support shell is removed from the mold.

53 - The first half of the support shell is removed from the mold.
 The two Rebound® halves are then opened for the first time.

54 - The two Rebound® halves are then opened for the first time.
 The second half of the Rebound® mold is places back into its support shell.

55 - The second half of the Rebound® mold is places back into its support shell.
 The mold is strong and light weight, the Rebound® has captured perfect detail of the original model.

56 - The mold is strong and light weight, the Rebound® has captured perfect detail of the original model.
 The mold halves are fitted back together and rubber banded in order to get ready for casting.

57 - The mold halves are fitted back together and rubber banded in order to get ready for casting.
 The mold is placed into a bucket and objects packed around it in order to keep it upright for the casting process.

58 - The mold is placed into a bucket and objects packed around it in order to keep it upright for the casting process.
 Smooth Cast® 320 will be used for making the castings.

59 - Smooth Cast® 320 will be used for making the castings.
 Smooth Cast® 320 is measured out 1:1 by volume.  No scales are necessary.

60 - Smooth Cast® 320 is measured out 1:1 by volume. No scales are necessary.
 The Smooth Cast® 320 is combined in a clean mixing container.

61 - The Smooth Cast® 320 is combined in a clean mixing container.
 The Smooth Cast® 320 is poured through a funnel into the mold.

62 - The Smooth Cast® 320 is poured through a funnel into the mold.
 Once cured, the mold is opened and the casting revealed.

63 - Once cured, the mold is opened and the casting revealed.
 The casting reflects perfect detail of the original model.

64 - The casting reflects perfect detail of the original model.
 The casting captured the character and detail of the original without doing any damage to the original antique!

65 - The casting captured the character and detail of the original without doing any damage to the original antique!

                   
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2000 Saint John Street, Easton PA 18042 | Order Desk: 800.762.0744 | Fax: 610.252.6200 | Tech Help: 800.381.1733 or 484.546.0466

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