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Making a One-Pour Mold
Making this type of mold eliminates the necessity of attaching the obverse to the reverse waxes as it is all done in one pour.

You begin with a finished medal in plaster which has been sealed with three coats of shellac thinned with methyl hydrate. Each coat of shellac must be thoroughly dry before the application of the next coat.
Place the shellacked plaster medal on a board or tile. Build a flat surface of plasticine half-way up the side of the medal.
Make the mold square so it stands up when the wax is poured. Use shellacked wooden slats for the walls of the mold. Support the slats with coils of plasticine which are applied very tight to avoid leaking of the liquid rubber. Apply small coils of plasticine on the outside and inside at the corners.

Extend the plasticine on the inside bottom to reach the slats. Press the end of your finger into the flat plasticine area. This makes indentations that act as registration keys for your mold. They hold the mold in place when the two parts of the mold are placed together. They will appear as bumps on the other side of the mold.
Add a plasticine wedge on the inside. This wedge becomes like a funnel for the wax pour.


It touches the slat and on the other end it is fastened to the medal.

You are now ready to make the rubber mold. Spray with Smooth On-Mold Release. Put on two thin coats allowing it to dry between coats. If you put on too much it will puddle. If this happens clean it up with a soft brush.

Mix Smooth-On PMC 121/30 Dry and apply as described previously on page 3. Allow the rubber to harden overnight.

The next morning take the mold apart and turn it over. Again build up the slats with plasticine coils to stop leaking. Shape the plasticine wedge so it is rounded similar to the other side.

Apply Smooth-On Mold Release to the medal and to the mold. Again, mix the rubber as before and apply it over the medal and the mold completing the back of the mold. Allow the rubber to dry completely.

When the rubber is hard take the mold apart and take the plaster medal out. Clean all plasticine off the rubber and wash the rubber mold in warm water and dishwashing liquid. Dry thoroughly.

Spray both sides of the mold with two coats of Mold Release allowing drying between coats. Fasten the two sides of the rubber mold together securely with rubber bands. Set the mold up with the pour hole at the top. Pour hot wax (200 degrees F.) into the mold. Pour until the pour spout is full. If the wax sinks down top it up. If the wax leaks stop the leak with plasticine.
Allow the wax to harden and cool completely before opening the mold. Cut off the pour spout and clean up the edges.
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