How to make a Rubber Hatchet (Theater Props, Cosplay)
Clean the hatchet using soap and water. Remove any dirt, dust, loose paint and rust.
Embed the hatchet into clay so that half the hatchet is showing then create Key holes (indents) in the clay. The key holes help the two mold halves line up.
Step 3: Coat the Hatchet with Mold Release
Mold release will help keep the ComposiMold from sticking to the hatchet.
Start with a thin layer of ComposiMold and continue to brush more layers as the ComposiMold cools and thickens. The mold should be at least 1/4 inch thick.
Once the ComposiMold has solidified, mix a batch of plaster of Paris.
Soak cheesecloth into the Plaster of Paris, and place at least 5 even layers of the Plaster soaked cheese cloth onto the rubber ComposiMold mold.
Once the Plaster has hardened it is time to de mold (The Plaster will harden after 3 hours). Remove the clay and the hatchet from the mold. Clean up the hatchet and the mold to prepare them for the second half of the mold.
Create keys in the mother mold so that the two halves fit together perfectly.
I used nuts in this example and glued them down with plaster. This will create holes in the second half allowing them to line up correctly.
Once the mold and hatchet are cleaned put them back together.
Lay saran wrap over the mold so that the Plaster doesn't stick to itself. Then do the same thing we did to create the first half of the mother mold.
De-Mold once again removing the hatchet from the mold.
When casting with silicone you can paint the mold with resin dyes or oil based paints.
Dye the silicone using resin dyes or oil based paint, then brush it onto the mold.
Quickly put the two halves tightly together, then top the mold off with more silicone.
De-Mold the rubber hatchet (the silicone took 16 hours to cure) Clean off any extra paint. Enjoy! Use it as a stage prop, for Cosplay, or for pranking your friends.