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Molds for concrete, plaster, soap, wax, chocolate, confections, and other casting materials!
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PMC Jewelers Clay and Poly Clay Molds
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Flagstone
Project by Wayne Nicholson
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Wayne sent us the finished photos of his flagstone walkway. What a fantastic job! When the grass grows back over the summer, it will make the perfect living border to a perfect landscape project. As a mold maker, you don't know how thrilled I am to see my vision of what my molds were intended to do come to life. As this was a first time project for Wayne in using the kind of molds I make, I have to say, his project reflects the great detail and time he put into it. Wayne added his own personal touch to these stones with the addition of colors and method. Something you cannot buy at a big box store! |
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 Image above showing cut stones meeting existing walkway. |
More
pictures at bottom of page.
In an email sent by Wayne on Feb. 24, 07 Wayne wrote:
Hi Dan,
I just finished my 4th set of molds. I have learned a couple things that might be helpful to your future customers.
The first thing is, that they work well and are easy to use. Even my first set is pretty good. Now, to the important stuff. I started with two 50lb bags of Portland cement and four 50lb bags of sand (2 to 1 ratio). I found that 1 1/2 bags of cement to 3 bags of sand will almost fill one set of 4x4 molds. On the next set I added 4 scoops of small gravel to each batch ( I mixed 1/2 bag of cement and one bag of sand at a time in a wheel barrel as a batch}. A scoop is the amount I could scoop unto both hands as I cupped them. This will fill a 4x4 set with just a little left. So, one set of molds require 75lbs of cement and 150lbs of sand and a little gravel.
Next the release agent, I tried Pam first because it is quickest. I found that if I put a good coating on it took 1 full 6 oz. can of Pam per set of 4x4 molds. I used it for 2 sets but it could get pretty expensive that way. Next I tried the canola oil. I poured a fair amount into one of the molds and used a small piece of cloth to wipe the other molds. This takes longer but works well and is much cheaper. Also the canola oil seems to clean up easier.
Next the dye. I think it would be pretty plain without some color. I decided to use black dye. I decided to use your suggestion and not totally mix the dye. This worked well After mixing the cement and sand I used the little red cap from the Pam can to measure. I started with 1/2 cap full, and sprinkled it on top then mixed it in a little. I mixed it as I walked around the wheel barrel a couple times. Then I put it in the molds and followed your directions. This came out well, kind of like marble. On the next couple batches I tried a little more dye and finally settled on about 2/3 of the red Pam cap. Since I am new at this I decided to lay them out next to each other to see the difference. After three sets I could see a difference in each batch even though I tried to use the same procedure. However after I moved some around between sets they looked pretty cool. I moved a few of the darker ones (a little more dye) to the lighter ones and visa versa. It looks pretty neat. Oh one thing, for the whole procedure I used THROW AWAY RUBBER GLOVES, that way when handling the molds or using the dye I could just throw them away. They are not to expensive and are worth it. Be careful of the dye it will stick to almost anything.
Next, marking the molds. I found on the first set of molds that it was difficult to find the letters so that I could mark the molds. Some were covered with cement some with oil. My solution was to take a small round file and file a small dimple in the edge of each mold directly across from each letter. This works excellent. Now I just scan the edge of the mold for the dimple and wipe that small area to see the letter. Works great.
Other hints, On my first set of molds I filled one at a time and moved them to my lawn to dry. This took allot of time. Now what I do is use 2x4s to make a quick table to work on. I use a small table in the middle and 4 foot ladders on the ends. 3 on one side and 3 on the other side. This gives me around 15 feet to put my molds on. I can set it up and take it down in about 2 min. then a put the release agent on all 11 molds at once and can fill them one after another quickly. It took me 2 1/2 hours from the time I started to set up to the time I finished cleaning my tools on the first molds. By the fourth set I had it down to about 1 hour and 45 min. start to finish
I hope some of this might be helpful to some of your future first timers like me.
Oh, I was wondering, if I somehow damage one of my molds is it possible to purchase a replacement ?
Thanks for a great product
Wayne
P.S. if you want I could send pictures
(Here are Wayne's pictures re-sized for the web that he sent)
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Four sets laid out and mixed for walkway. |
Close-up of single stone showing marble affect. |
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One set of 11 stones. |
Getting setup for casting. |
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Concrete color sprinkled on batch before lightly mixing in. |
Showing notch next to letter and letter scratched in back. |
In response to Wayne's question about purchasing single molds for replacements: Yes, single molds can be purchased to replace any damaged or worn out molds. Simply write me and I am happy to work with customers to make sure they get what they need to finish projects.
Thank you Wayne for sharing the great photos and comments on your project!
Click Here for a link back to Flagstone set