The Instructable you've all been waiting for!
Originally I was going to just buy a few professionally made break away bottles, but I had sticker shock and figured I could just make them myself.
Here is a popular supplier of all things break away glass.http://www.alfonsosbreakawayglass.com/shop.php
Here is a "Budweiser" bottlehttp://www.alfonsosbreakawayglass.com/shop.php?main=Glass&sub=Bottles&subsub=Beer+Bottles
But wait how much for shipping?
1 #108 BROWN LONG NECK BEER BOTTLE $16
PACKAGING CHARGE $10
SALES TAX: $2.15
Almost $30.00 for 1 bottle!
However you can order up to 4 bottles for the same shipping/packaging price so maybe closer to $20.00 But they don't guarantee the bottles after the package has left their hands and that it will make it in one piece.
So that wasn't the route I was going to take and instead started researching how break away glass was made. After emailing a few people I learned that professionals use a special type of resin instead of "sugar glass". Although either will work.
I recommend watching this video by "Indy Mogul" to get a feel for what's being done. He uses sugar glass but the techniques work just the same for resin. Candy glass is also still a cheaper route to go.http://youtube.com/watch?v=GqkSDkHOots&feature=relatedMaterials:
1 dedicated cooking pot ( I used a dollar store pan)
1 dedicated candy thermometer
Break Away glass resin
Resin dye (I used brown, comes in a 2oz bottle)
Silicone (tin or platinum cured, don't need a lot, about 6 lbs total)
mold release spray ( there are other options explained later)
foamcore/legos to build the mold (I used foamcore with a glue gun)
I decided to try tin-cure silicone, it's a little bit cheaper than platinum cure and works just the same. It however doesn't last as long as platinum cured.
I purchased the silicone and brown dye from Smooth-On:http://www.smoothonsecure.com/store/product_info.php?cPath=278_279_281_80&products_id=392&osCsid=45268e37fd4d3661fda645fbed0b87db
The brown dye is translucent and does a real good job of simulating brown beer bottle glass.http://www.smoothonsecure.com/store/product_info.php?cPath=291_270_28&products_id=541&osCsid=c588d75e90bc12b5c0d34e73fb8e80a3
The resin i used had a generic name of "break away bottle blend"
It's a combination of Piccolastic and Piccotex which are also generic names. Piccolastic is more elastic while piccotex is more brittle. They are all reusable, in the sense that after you break them or if a mold didn't come out perfect you can remelt them. I don't know about how green recyclable they are though. And definitely not edible, very nasty, like a mouth full of sand.
I ordered from a place called "Special Effect Supply Corporation", has a family-run feel, based out of Utah. However I could have saved a lot more money if I had bought locally. On the Smooth-On website I found a distributor for their products that also carried the "break away glass" resin.
Check out a local distributor for smooth on products, chances are they will have the Break away glass resin (Piccolastic/Piccotex) products as well.http://www.smooth-on.com/distrbtr-2.htm
Here is the resin. One can buy in different quantities. (Buy locally though)http://www.fxsupply.com/catalog/index.php?cPath=152
I also ordered the DVD on break away bottles. (PM me if you want to see it)http://www.fxsupply.com/videos/videos.html
Also ordered mold release spray:http://www.smoothonsecure.com/store/index.php?cPath=278_279_282_304&osCsid=30362f3d080392f208f38ec6c450817f
Here is where I should have ordered the materials. They had everything I needed and cheaper.http://www.artstuf.com/
However not everything is listed on the website.
They are in fact cheaper than Smooth-On. Smooth-On charges more to encourage it's customer to shop locally.
Now to construct the mold...