Re: First Mold/Cast - iron man
Look up Rebound-25 on Smooth-on.com. I would order a gallon, it's cheaper in the long run and the trial size isn't enough. the key to mold making is to do it right, don't go "oh instead of 4 coats I'm just going to do 3 because it will save me silicone and $." if you do that you will most likely have to re-mold.
Smooth-on.com also has some tutorials on mold making, as stated above I would make atleast a two part mold. Find a distributor near you to save on shipping and order everything at once. Make sure you get Plasti-paste 2 so you can make a shell, some silicone to silicone mold release is a must, some silicone thickener, and I would go with smooth-on's Roto-Casting Resin.
When molding ALWAYS have a clean area, clean mixing tools, clean brushes, NON-latex gloves, glasses are always a good idea, and make sure that you seal your sculpt with a clear-coat and it is dry(if not sealed silicone won't cure, if clear-coat isn't dry the silicone will have a "tacky" layer).
Start out by mixing enough to easly cover the whole model, as soon as you mix it pour it on top of the model at a medium rate. Let the silicone get into every part of the model, as this will be your detail layer (you will have to brush some into the parts that are hard to get).
I usually let it cure completely until it is not tacky, then I repeat that step and as soon as it is tacky, but doesn't stick to my finger, I apply a layer using the silicone thickener. do this until you have a mold 1/2" to 3/8" thick.
Now you need to build up a barrier, this is where the mold will be parted. before the barrier cures I place some styrene sheet in the silicone to creat a wall. Now starting on one side build up your shell using Plasti-Paste, once it's thick enough(1/2" to 3/8") and cures remove the styrene and apply a mold release to the Plasti-Paste(I've heard bees-wax works). Repeat the Plasti-Paste step until you have a complete shell, then carefully remove the shell from the silicone.
There should be a crease in the silicone where the styrene was, carefully use an X-atco knife and cut through the silicone down the crease. Carefully take the silicone off the model and store it in the shell until you are ready for casting.
I hope this helps!
Superprops