Ok, so your customers really really want a Rabbit just like the ones at Walt's Mart. So, that means you'll need to use commercial Plaster molds, and expensive equipment... but wait- you one have 5$? no problem this instrucables will show you how to build a drain tank and how to make your own casting slip for very little money.
Step 1: Acquiring the Parts
for this build yoiu will need : A plastic Bus box from a resturant supply housem or a large plastic tub with sturdy sides. the bus box I bought cost 2.45 at Smart and Final. you will also need a 3/4 plastic Conduit hose nipple connection (1.50$) a short piece of 3/4 inside diameter hose, and a 3/4 inch drill....
you will also need some pieces of scrap wood. tp ,ake the rack.. a old refrigerator shelf will work as well..
Step 2: Assembly
drill a 3/4 hole in one of the low spots in the bottom of the bus box, and install the conduit with the nipple pointed down, attach the hose, build a frame (rack to fit on top of the tub...thats it...
Step 3: Making Inexpensive Casting Slip Form Scrap Clay
take anough scrap clay to fill a 5 gallon bucket about 4/5 the way up. chunks arnt important that this time, cover with water and let stand over night.
the next morning add the following- (both chemicals available for cheap from a ceramics supply place) use gloves and eye protection when handling both chemicals
Sodium silicate 2 oZ
Soda ash - about 1 teapoon
use a drill with a mixer attachment and blend for about 10 miniutes add water until you get a cake batter )or thinner mix) let stand. the mix will thicken up over night- next morning mix again and use to cast.
Step 4: Use and Results
when you mold is finished (10-40 miniutes) run the hose back into the bucket of slip, and dump the contents of mold into the tank-
you can keep adding scrap and water to the slip bucket until the casts start to stick inside the molds, once that happens, just add a small amouts of the Silica Dioxide and Soda ash and mix...
these skulls where cast form a commercial mold using recovered Navajo White clay. washed with black and brown underglaze, wiped back and then fired to cone 5