damn, that sucks, have been busy that last couple days otherwise i would have helped ya out with the silicone mold. i only got a chance to see the updates now.
that's a lot of silicone. did you make your clay layer really thick? or did you have a leak? i always use hot glue to seal up the mother mold to the mold walls.
but for my bios, when i do the matrix mold, i end up using a little over a gallon. this way def uses more siiicone than brushing it on.