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Step 1
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Step 2
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Measure and cut a 3 inch section from a 4 3/4 inch diameter shipping tube in order to create a "mold box" |
Apply Seal-Dit TM to the inside of the mold box and wipe away any excess, leaving the inside coated and shiny. |
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Step 3
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Step 4
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Roll out Safe-D-Clay TM so that it is larger than the diameter of the mold box and about 1/4 to 3/8 inch thick. |
Place mold box on top of Safe-D-Clay TM and trace around inside of mold box to score the clay and leave a circular impression. |
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Step 5
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Step 6
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Cut out circle of clay with a sharp knife. |
Apply a thin coat of Seal-Dit TM to the top of the clay circle. Apply only enough to make the surface shiny. |
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Step 7
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Step 8
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Place glass diamond, top side down, in the exact center of clay circle. The Seal-Dit TM applied in Step 6 insures good contact. Do not press diamond down into Safe-D-Clay TM circle. Glass diamond should rest on the top surface only. |
Apply a strip of Safe-D-Clay TM around the entire glass diamond flush with the edge, which represents the widest part of the diamond. |
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Step 9
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Step 10
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Press Safe-D-Clay TM to achieve full contact with diamond and trim with a modeling tool to ensure a level, tight connection between clay and diamond. |
With a modeling tool, carve circular indentations in the clay flange surrounding the diamond. Notice three indentations close together to ensure proper orientation of the mold when assembled. |
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Step 11
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Step 12
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Apply a thin coat of Release-Dit TM to the top of the clay flange, including the indentations surrounding the diamond. |
Measure the height of the diamond as it rests in the "clay bed." In this example we have a height of 2 3/8 inches. |
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Step 13
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Step 14
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Adding 1/2 inch to the height of the diamond set in the clay bed will determine where to mark the inside of the mold box to establish the CopyFlex TM fill height. In this example the mold box was marked 2 7/8 inches up from the bottom. |
Using Safe-D-Clay TM, form a cylinder 1/2 inch in diameter by 1 inch long and connect it to the diamond by pressing it down on the point until it is flush with the glass diamond all the way around. |
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Step 15
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Step 16
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Shape the clay to match the facets of the diamond by cutting down the sides of the clay cylinder in line with the facets of the diamond. Apply a thin coating of Release-Dit TM to the clay cylinder. |
Wash diamond with a light mixture of dish soap and water to remove fingerprints and any excess Safe-D-Clay TM and Release-Dit TM. Dry with a soft lint free towel. Diamond must be very clean and buffed to a high shine. |
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Step 17
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Step 18
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Place mold box over the diamond & clay bed assembly and press the clay bed with a modeling tool against the inside of the mold box so that the clay is completely sealed against the inside wall. |
Combine and mix 22 ounces (11 oz. of Part A and 11 oz. of Part B) of CopyFlex TM Liquid Silicone and pour into mold box up to the fill line. Allow to cure undisturbed for five to six hours at 70 degrees F. |
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Step 19
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Step 20
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Once the CopyFlex TM has cured, turn the mold box upside down to reveal the clay bed made from Safe-D-Clay TM. Remove the Safe-D-Clay TM and wash the exposed portion of the diamond with dish soap and water. Dry and buff glass diamond to a high shine with lint free towel. |
Using a natural bristle artist's brush, apply a thin but thorough layer of Release-Dit TM on the entire CopyFlex TM Silicone flange area that surrounds the glass diamond. |
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Step 21
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Step 22
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Combine and mix 10 ounces (5 oz of Part A and 5 oz of Part B) of CopyFlex TM Liquid Silicone and pour into mold box until it is completely filled. Allow to cure undisturbed for five to six hours at 70 degrees F. |
Using a sharp knife, place a small cut along the spiral seam of the paper tube and then tear the paper mold box away from the cured CopyFlex TM mold. |
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Step 23
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Step 24
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Separate the two sides of the CopyFlex TM mold and remove the diamond and the clay cylinder used to make the pour hole used to fill the mold cavity. |
Wash the new mold with hot soapy water, rinse and dry with a lint free cloth. This mold is dishwasher safe. The mold is now ready to use. Notice the unique configuration of alignment keys that ensure perfect assembly and the pour hole that was created by the Safe-D-Clay TM cylinder. |
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Step 25
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Step 26
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Assemble diamond mold using four #84 rubber bands. Pour ClearCut TM Isomalt into mold at 265 - 275 degrees F. To lessen the pitting effect of silicone on Isomalt, fill mold 1/3 full and roll to coat inside and then pour out any extra. Wait until the Isomalt coating hardens then fill the entire mold with more Isomalt and immediately drain the mold once again. Allow Isomalt coating to harden. Fill mold entirely for a third time and un-mold when completely cooled. |
If properly made, the diamond mold should produce an exceptionally shiny sugar gemstone that is almost water clear with sharp edged facets. Storing ClearCut TM Isomalt diamonds in sealed containers with silica gel packets will insure a good shine and clarity for months. |