Introduction: Cast Concrete Mono Speaker
This is a step by step instruction set on how to make your very on skull mono speaker. The process should work for any other shape or designs. The pictures on the left are actual final product photos. Other paint finishes can be applied however I decided to go for a trophy style of finish.
THE FILES ATTACHED TO EACH STEP IS A TIMELAPSE OF THE PROCESS FOR YOU TO DOWNLOAD AND VIEW.
Step 1: Sculpting the Design
In this stage i started of with a Styrofoam manikin head. From this i referenced skull images to understand the basic process and form of the human skull. As you can see in the video above I added Plasticine and clay to build up the features of the skull and to add the headphones. This can be done with just basic wooden sculpting tools. I also added mudrock to the outside of the mold to set and then use as a negative in the next stage.
Step 2: Mold Manufacture
I used 1.5 inch mdf to create the containment area for the mold. From this stage i cut in half the mold from the previous step using a bandsaw and removed the Styrofoam inner. From this point i then placed half of the mold into the containment area and sealed it using silicon gel. I used plaster of paris to make sure the mold was sturdy. I slowly mixed up the plaster of paris and then poured it around the outside of the mold. This took around 1 week to set firmly in place. I used a cardboard tube such as the one you get from a carpet roll. to create the hollow tube in the center of the skull.
Step 3: Final Assembly
I created a circuit for my product that was purchased from Kitroniks. After assembling the circuit i then placed it into the hollow section in the concrete shell. Fro the speaker cover i used a recycled speaker ear cover to create the illusion of an actual headphone. After this was all set i could move on to painting the product. Fro this i used black and copper acrylic paint to create a trophy effect.