How To Make a Brush On Mold of an Antique Rifle

A 19th century historical long rifle is going to be used to make museum-quality replicas of this important piece of American history.

First, 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. A foam plug is then made out of ear plugs and 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.

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. Keys are cut into the clay with a Popsicle stick in order to register the two silicone halves when cured.