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Welcome to Faux Fossil Building. I chose the Tyrannosaurus Rex because of my own Childhood Dreams of Owning a fossil of my very own. I will show you how to build a T-REX using recycled paper, recycled cardboard and a home made mold.
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Step 1: Things you will need

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What you will need.
1. Hot Foam Cutter $20.00 USD(optional) of a Steak knife (free).
2. Foam Insulation $2.50 USD
3. Paper (recycled)
4. Cardboard (recycled)
5. Plaster $13.00 USD
6. Blender
7. Oven
8. Coffee
9. White Glue $2.00
10. paint brush

Step 2: A good picture

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I found a picture of a T-rex on the Internet. I traced the image using Illustrator or you can free hand if you feel comfortable. Just make a Pattern that suites you.

Step 3: Tracing Patterns

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I blew the Image up using a graph. I made the T-rex the size that I wanted. Use Signboard or Cardboard when making the graph for your resize. Signboard helps to keep your knife or foam cutter steady while tracing the outlines.

I then used an exacto knife to cut out the T-rex pattern. I Glued the cut out Pattern to the Foam using white Glue only, spray glue will melt the Foam. I found this out the hard way and had to make a new foam T-REX.

Step 4: Cutting Foam

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Cut out the Foam using either a Hot Foam Cutter of a Steak knife. I found out both work just as well and a Steak knife is free.

Step 5: Make a Mold

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Make a Mold of your Foam T-Rex Using Plaster of Paris. Make sure you glue (white Glue) down Foam original to Wax Paper. This will allow Plaster to release from the surface that you place it on and by gluing it down you will not have any under cuts under the plaster.

Spread Plaster evenly over your original at least two inches thick. Spread plaster at least three inches past the boarder of your original.

Let plaster shell dry for 24 hrs and then demold.
Wondering of using this method for a school project. Wondering how much the final product roughly weighs. Thanks
John Sielaff (author)  mckinlay-boy4 years ago
It is really lite. Maybe 5lbs.
John Sielaff (author) 6 years ago
Thank you Porcupine mamma I had alot of fun making this project. I will be posting some more in the future.
I like it! I like it! :0)
This is so creative! I am going to try it with my kids this summer.
bobjoy6 years ago
Very creative and cool John. My grandson will love this.
shanewinn6 years ago
Great project one of the best!
John Sielaff (author)  shanewinn6 years ago
Thanks Shane I am glad that you like my project.
Oblivitus6 years ago
Step 1:Litter. Step 2:Wait 10 million years.
John Sielaff (author)  Oblivitus6 years ago
My T-rex only takes a couple of hours instead of Millions of Years.
Yeah, but my plan takes less work. :)
I am going to give this to my daughters school they will love it!
John Sielaff (author)  dwinn34436396 years ago
It does make a good project for kids the material is recycled and non toxic.
fish finder6 years ago
this gets my blood boiling!
scral6 years ago
Pretty cool! Looks like you could make just about anything you want with this method!
John Sielaff (author)  scral6 years ago
Yes you could make any model that you wanted and make anything out of Paper.
DIYDragon6 years ago
That's pretty cool. I always wanted to make a table or something with some 'faux fossils' in it. I'll remember this, and see if I can make it work. : )
John Sielaff (author)  DIYDragon6 years ago
To make a Table Top I would use Cement instead of the Cardboard method. Cover your original with Silicone Caulk first and after that has dried then pour your plaster over the Caulk Shell. Your Plaster will form a mother mold and then you can pour your cement into the Silicone. Instead of using coffee to color your T-rex use acid in varying strengths. This method will make a better table top. The T-Rex I made from Paper is a better wall hanging because it is light and easy to hang.
mg0930mg6 years ago
This is really cool. I love this. Five stars. Favorited.
John Sielaff (author)  mg0930mg6 years ago
Thank you. This is my first Instructable I love to make things and this web site has really helped me out with alot of my projects.
Oh yes. Sorry, forgot to do this. WELCOME TO INSTRUCTABLES!1!!!!!1!!11!1!11!!1!1!!1!!! /dramatic welcoming. In all seriousness, I hope you show more of your amazing projects on here.
John Sielaff (author)  mg0930mg6 years ago
Thank you for welcoming me. This is the best web site and community that I have ever come across. I will post more projects. I have a Ton of em that I have made throughout the years.
Yay! Subbing.
ChrysN6 years ago
That looks really cool! We get a lot of foam like that at work as packaging material, I've wondered if there is a good use for it.
John Sielaff (author)  ChrysN6 years ago
Foam is great and easy to work with.