OK, more prototyping. I decided to make a rock face mold using silicone caulk purchased at a Dollar store (Red Devil brand). While searching for techniques using caulk reminded me of an old engineering saying: "The wonderful thing about standards is there is so many to choose from". I found so many methods and tried a few which didn't work of course (didn't try the Dawn soap one).
So what I learn, the critical ingredient on using silicone caulk for molds, add liquid glycerin to the mix. Silicone needs moisture to cure, the glycerin adds the required moisture and my first test cured in 4 hours. So my recipe is:
2 fluid ounces (50 grams) 100% silicone caulk
2 fluid ounces (40 grams) corn starch/flour
~1 fluid ounces paint thinner (25 grams) (100% mineral spirits)
1/4 teaspoon glycerin
a few drops of acrylic paint, acts as a mixing guide.
First, making the rock face:
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Using heavy duty aluminum foil, I apply a thin layer of polyurethane gorilla glue inside the black lines shown above. Using a spray bottle, I misted the glue with water which acts as a catalyst for the glue. I added double stick tape to seal up the glue. The idea here, once cured the glue will harden my rock face template. I folded the top piece over then crumpled up the foil. Next lay it out shown below:
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I build a small box using plywood with metal flashing attached to the side and put the template inside the box shown below:
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For a mold release, I used petroleum jelly (vaseline). So after a heavy lube job, fill with the silicone mixture:
View attachment 134252
I add some small blocks of wood for support, I want to bend the mold to make curved rocks. So here how it came out:
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It is very soft, my guess it's hardness is Shore A: 25. It will bend very easy, hopefully I can make more realistic rocks using a mold. So for my first test on making a rock....sorry but it's cliffhanger time, that's my next on my list. So stay tuned...