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Taking the Mystery Out of How to Make a Concrete Sink Mold

With more and more architectural concrete companies offering various decorative sink lines, we present the following “how-to” guide so you too can make your own. Concrete is an attractive material with a unique quality look and feel. Concrete is a "perfectly imperfect" material, it will vary from piece to piece and that is part of its charm and uniqueness. 

The following step-by-step uses Smooth-On's VytaFlex® 40 mold rubber to achieve perfect concrete sink molds that can handle multiple castings. Just remember that you can make a mold of just about anything so get creative in designing your new sink basin.

 The model: concrete sink basin.

1 - The model: concrete sink basin.
 Sink basin is measured for dimensions. Acrylic coated boards are used to construct the mold box walls, spacer board and two baseboards.

2 - Sink basin is measured for dimensions. Acrylic coated boards are used to construct the mold box walls, spacer board and two baseboards.
 Basin is centered on the acrylic coated board.

3 - Basin is centered on the acrylic coated board.
 A pencil outline is drawn around perimeter of basin.

4 - A pencil outline is drawn around perimeter of basin.
 Use a jigsaw to cut out the
circular pattern. This will be used as a spacer.

5 - Use a jigsaw to cut out the circular pattern. This will be used as a spacer.
 Remove plug.

6 - Remove plug.
 Place sink on baseboard and place spacer on top.

7 - Place sink on baseboard and place spacer on top.
 Mark alignment on baseboard and spacer board.

8 - Mark alignment on baseboard and spacer board.
 Use modeling clay (sulfur free) to create gasket around perimeter of basin.

9 - Use modeling clay (sulfur free) to create gasket around perimeter of basin.
 This will prevent rubber from going underneth model.

10 - This will prevent rubber from going underneth model.
 Placer spacer down over basin.

11 - Placer spacer down over basin.
 Use modeling clay to fill in negative space caused by the spacer.

12 - Use modeling clay to fill in negative space caused by the spacer.
 Glue down acron nuts in corners for registration keys.

13 - Glue down acron nuts in corners for registration keys.
 Place one extra acron to help with alignment.

14 - Place one extra acron to help with alignment.
 Assemble mold box with drywall screws.

15 - Assemble mold box with drywall screws.
 Seal seams with hot melt glue.

16 - Seal seams with hot melt glue.
 Release all surfaces with Universal Mold Release.

17 - Release all surfaces with Universal Mold Release.
 Measure and dispense VytaFlex® 40 mold rubber.

18 - Measure and dispense VytaFlex® 40 mold rubber.
 Mix thoroughly for three minutes, scraping bottom and sides of container.

19 - Mix thoroughly for three minutes, scraping bottom and sides of container.
 Pour VytaFlex® mold rubber 40 slowly over model. DO NOT COVER BOTTOM OF ORIGINAL MODEL. Exposed area will represent pour spout.

20 - Pour VytaFlex® mold rubber 40 slowly over model. DO NOT COVER BOTTOM OF ORIGINAL MODEL. Exposed area will represent pour spout.
 Let VytaFlex® 40 mold rubber cure for 16 hrs. at room temperature  (72°F / 23°C).

21 - Let VytaFlex® 40 mold rubber cure for 16 hrs. at room temperature (72°F / 23°C).
 Use modeling clay to fill in any surface irregularities.

22 - Use modeling clay to fill in any surface irregularities.
 Place reverse baseboard down over cured rubber.

23 - Place reverse baseboard down over cured rubber.
 Secure board with drywall screws.

24 - Secure board with drywall screws.
 Turn over mold box.

25 - Turn over mold box.
 Remove original baseboard to expose model.

26 - Remove original baseboard to expose model.
 Remove spacer board.

27 - Remove spacer board.
 Remove clay gasket and wipe surface clean.

28 - Remove clay gasket and wipe surface clean.
 Fill any screw holes with modeling clay.

29 - Fill any screw holes with modeling clay.
 Hot glue exposed seams.

30 - Hot glue exposed seams.
 Apply Univeral® Mold Release to all surfaces.

31 - Apply Univeral® Mold Release to all surfaces.
 Measure and dispense VytaFlex® 40 mold rubber.

32 - Measure and dispense VytaFlex® 40 mold rubber.
 Mix thoroughly for three minutes, scraping bottom and sides of container.

33 - Mix thoroughly for three minutes, scraping bottom and sides of container.
 Pour VytaFlex® 40 mold rubber over model and existing rubber to create second half of mold.

34 - Pour VytaFlex® 40 mold rubber over model and existing rubber to create second half of mold.
 Let VytaFlex® 40 mold rubber cure for 16 hrs. at room temperature  (72°F / 23°C).

35 - Let VytaFlex® 40 mold rubber cure for 16 hrs. at room temperature (72°F / 23°C).
 Once cured, remove mold box side walls.

36 - Once cured, remove mold box side walls.
 Slowly remove top section of mold.

37 - Slowly remove top section of mold.
 Remove original sink basin.

38 - Remove original sink basin.
 A perfect 2-part mold of the original model.

39 - A perfect 2-part mold of the original model.
 Apply In and Out II® release
agent to all surfaces.

40 - Apply In and Out II® release agent to all surfaces.
 Place mold between boards and secure.

41 - Place mold between boards and secure.
 Place mold on a vibration table and fill with concrete.

42 - Place mold on a vibration table and fill with concrete.
 After concrerte cures for 24 hours, demold casting.

43 - After concrerte cures for 24 hours, demold casting.
 A perfect concrete reproduction of the original.

44 - A perfect concrete reproduction of the original.
 Rubber mold is ready to be cast again.

45 - Rubber mold is ready to be cast again.


Taking The Mystery Out Of Creating A Concrete Sink Mold

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