First post! Woohoo! First off, this forum is HUGE and full of just incredible talent. I can't believe I haven't signed up years ago and now I'm proud of being a part of this enormous community of fellow movie prop fans.
I figured I'd like to share my first resin casting nightmare... er, project here, a scaled-down replica (though still large) of the top section of the Idol pedestal.
Here is the master pattern in the works. It's made of foam with carved details, later coated with an air-drying modeling compound. Once dry it's hard as a rock.
Beginning stage. The pillar segment is two round cut pieces of foam. The top and bottom surfaces are 1/2" foam core board.
After tracing on a template of the side pattern, the carving begins.
Added air-hardening compound.
Top portion completed. Tooled in some stone-like texture and cracks.
Bottom portion complete.
Sculpting the side pattern.
A completed section of the side pattern with added textures.
Completed master pattern. Ready for moulding.
This project's been a nightmare to finish and it's claimed our breakfast table for over a month... but I got it done! The molding process was a near disaster, but in the end, after some ingenuity, and some online help from an expert model-making friend of mine I was able to rescue it. This casting is semi-solid resin. Basically about an inch thick outer layer of resin and a solid foam interior. It's still super heavy though at about 20 pounds or so.