Step #4 Casting

After you have finished making your mold and the silicone has cured you can begin casting. The casting process is easily the longest and most difficult stage of making a mask. For my mask i used West System Brand epoxy resin (Fig. 5). This kind of resin is usually about eighty bucks. However the only reason i used it is because i got it for free from work. Epoxy resin does work pretty well but you can also use polyurethane resin as well. The problem with epoxy resin is that is has to be applied in relatively thin layers at a time and allowed to dry. If you try to put it on all at once the resin will pool at the bottom of the mask and make it unwearable. The good thing about polyurethane resin is that you can let it thicken slightly before applying it to the mask so it doesn't run as much. Both epoxy resin and polyurethane resin are two part systems. This means that you have to mix a catalyst into the resin in order to harden it. If you don't mix in the catalyst the resin will not harden at all. Before you are ready to apply the resin to the mold your going to need a few things. A respirator is always a good idea especially if your working with a cheaper resin. Usually the cheaper the resin is the more it stinks. You will also need a lot of paint brushes to apply the resin, latex gloves, a container to mix the resin in, and something to mix it with. In a well ventilated area mix the resin together and apply it to the mold (Fig. 6). Then let it dry. Repeat this process until there is a relatively thick layer of resin on ever side of the mask. Then you are ready to add your fiberglass.