Carl Church Bird Taxidermy - Breakthrough Magazine Issue 89

MOLDING & CASTING
S TAXIDERMISTS, WE ARE ALL STRIVing to make our work stand out in front of
our competitors work with accurate anatomy, finishing, and composition. Our work
needs to have realistic groundwork to elevate the standard of our mounts.
This article is to show you a few techniques I use
when molding and casting large impressive rocks.
These are the rocks we all see with large cracks, shaped
edges, and uneven voids.
BREAKTHROUGH Issue 89
The rock I chose was 25 high, 18 wide, and 16

deep. The rock you choose should have multi angles
and levels. Molds are not cheap to make so the more
variations you can get from one rock mold the better.
(These rocks are harder to find than you think.)
1. Full Rock Table Mount
2. Half Rock Table Mount
3. Half Rock Landscape
4. Half Rock Wall Mount
Page 67
MOLDING & CASTING

The rock was placed at a good working height
with ample working room around the rock. All the
loose soil and moss were cleaned off with a soft brush.
Using a toothbrush, I worked around the rock cleaning out all the small cracks and fine details.
7a
11
7b
11. Apply silicone over the valve to secure it to

the mold. A final coat of thick silicone was worked
over the rock. On a rock this size I want a good
(5mm) layer of silicone over it at this stage.
The next problem was that the rock had several
voids which needed to be filled to create a smoother
rounded shape and to make a more simple backing
jacket.
12
5. Silicone rubber was brushed over the rock,

working it into the cracks and crevices. Once it fully
covered the rock, I used a hair dryer set on a cool-fast
blow setting and moved slowly over the rock. This
removed any air bubbles trapped in the cracks and
details of the rock.
tube. (The rest of the inner tube can be cut into strips
for reinforcing strips.
Cutting across the tube 8
makes large and very
strong rubber bands
which come in handy
for strapping together
small molds.)
8. Wash the valve
and cut around the edges so it will follow the shape of
the rock.
6
9
9. Cut a small X through the silicone mold down

to the rock beneath. This was done at the top of the
rock, but can also be done on an edge of the mold.
12. Using a wire brush, I scraped apart a piece of

polystyrene packaging to use as a filler. This was perfect as it was bulky and flexible.
13. I added the polystyrene to a small amount of
silicone, mixed it in well
13
to produce a putty-like
filler.
14. This photo
shows the large voids
filled in with the filler.
Once fully cured, a final
coat of silicone was
worked over the rock,
bringing the final thickness of the silicone to
(8mm).
10
14
6. Once the first coat was fully cured, thixtropic

additive was added to the second coat, which thickened the silicone so it became spreadable. A good
coat was worked over the rock, mixed in small
amounts to give me more working time.
To extend the life of the mold, I built an air valve
into the silicone mold, which was used to blow air
into the mold to help release the casts without putting
too much stress onto the silicone mold.
7ab. I use the valve from an old inner tube to
make a mold valve. First, remove the valve from the
Page 68
10. Glue the valve to the rock using silicone.

Make sure the valve is over the X.
15
'03.4"7"*-"#-&
15. Once the rock was covered in the final coat
of silicone, I generously coated it with talcum powder
and smoothed it by hand.
16
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#MBDLCVDL
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16. When the silicone was fully cured, all the

talcum powder was removed and any unwanted silicone was trimmed from the edges of the mold. Now
I drew a line over the mold to use as a guide to follow
when making a backing jacket.
17
17. For making a backing jacket, I tried out a

plastic paste, a new material to me. There are many on
the market, and the one I used is a Smooth-On product called Plasti-Paste. Its a two-part product that is
clean, very easy to use, and has a fast setting time of
around 8 minutes.
Page 69
MOLDING & CASTING

18
21. I now connected a foot air pump to the

valve, and pumped just a small amount of air into
the mold to help release the silicone.
22
25. This photo shows the artificial rock, straight

from the mold with no finishing work done, next to
the real rock.
26
23
18. As I worked the plastic paste over the rock,

I used playing cards as separators between the two
halves of the jacket.
19
19. The area around the valve can be very loose

as the strength of the valve will support the mold.
20. I used 5
20
killograms of Plasti-Paste on this
backing jacket, but
ran out when I got
to the flanges, so
these were built up
with a little Bondo
just for extra strength. The flanges were drilled to take
small bolts before releasing from the mold. Then the
playing cards were removed.
22-23. The rock was removed and the silicone

mold placed into the backing jacket and bolted together. I drilled screws around the opening into the
jacket to be used as anchors. Thin wires were pushed
into the silicone mold around the edge, then bent
over and wrapped around the screws in the jacket.
The resin mix I used was the same one I used in
my previous article in BREAKTHROUGH (see Issue #84,
page 77, Competition Base Work with a Difference). The mixture was worked into the mold, pushing the resin into the details, but not trapping any air
in the mold. Once fully cured, a second coat of the
same resin mixture was worked over the first, producing a thickness of about (5mm). Then I layered the casting with 2 ounces of fiberglass matting.
The casting now should have a thickness of around
(8mm) of resin.
Once fully cured, the casting was removed from
the mold using the same techniques as removing it
from the original rock. This was finished the same
way as the gargoyle was in my article in Issue 84.
24
21
24. Here is a closeup of the cast rock details.

25
Page 70
27
26-27. The cast rock was given a base colour. I

did this with thinned
wood stain, giving
one complete coat,
working the stain into
the cracks and details
of the casting. This
dried quickly. I then
gently rubbed over
the casting with steel
wool just to highlight
areas which stood
proud. I used several
coats of an oil-paint
wash to get the correct finish. n
CARL CHURCH is a bird specialist taxidermist
based in North Yorkshire, England. You may contact
him through www.birdtaxidermy.co.uk.

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MOLDING & CASTING

The rock I chose was 25 high, 18 wide, and 16

MOLDING & CASTING

11. Apply silicone over the valve to secure it to

5. Silicone rubber was brushed over the rock,

9. Cut a small X through the silicone mold down

12. Using a wire brush, I scraped apart a piece of

6. Once the first coat was fully cured, thixtropic

10. Glue the valve to the rock using silicone.

16. When the silicone was fully cured, all the

17. For making a backing jacket, I tried out a

MOLDING & CASTING

21. I now connected a foot air pump to the

25. This photo shows the artificial rock, straight

18. As I worked the plastic paste over the rock,

19. The area around the valve can be very loose

22-23. The rock was removed and the silicone

24. Here is a closeup of the cast rock details.

26-27. The cast rock was given a base colour. I

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