This project began when I found a halloween basket of Darth Vader on sale after Halloween – $2.50. I’ve been looking for project to learn/practice/experiment with silicone molds, so I chopped up the mask to make a two part mold.
![](https://www.acemonstertoys.org/wp-content/uploads/2016/12/IMG_4245-300x225.jpg)
I wanted the cavity to remain hollow so it could serve as a planter, so I built a box out of foam core and hot glue and placed the mask face up. I placed one edge of the foam core right up against the top of the mask to block out the cavity – lots of hot glue on the underside to keep the silicone out.
Despite having watched a variety of videos on youtube, i tried a different process to make the two piece mold in two separate boxes. Big mistake!
![](https://www.acemonstertoys.org/wp-content/uploads/2016/12/IMG_4242-300x225.jpg)
The mold had great detail, but the two pieces didnt match up. I tried to patch and fill, and it probably can be done, but i was in a rush to get on a plane and try to cast one of these for x-mas. The result was some unevenness in the bottom, and spalling out of the sides which could be cleaned up better.
![](https://www.acemonstertoys.org/wp-content/uploads/2016/12/IMG_4241-300x225.jpg)
I also didn’t pour it up high enough to the top, in part because my solution for the cavity was a failure due to lack of proper materials and time. The details came out pretty well despite taking it out too soon.
I also experimented with some concrete coloring agent and made this death star paper weight. I prepared too much material so I poured a bit of Darth’s mask to see how the color would be.
![](https://www.acemonstertoys.org/wp-content/uploads/2016/12/IMG_4244-300x225.jpg)
![](https://www.acemonstertoys.org/wp-content/uploads/2016/12/IMG_4243-300x225.jpg)
Its hard to see the color in the death star due to the lighting, but the mask shows the much darker charcoal color than the planter. I think with some added colorant, it would be a nice deep black.
The mold required ALOT of material. The stock we had at AMT was expired and hard when I opened the bottle, and it ended up taking 3.5 bottles, so essentially $100.
It was like taking a class for $100, which I’d have paid anyway, and I’ve got a half decent mold that can be used. Im not sure how I would try making it again so that the molds could better align due to the cavity I want to keep. If it were a solid head, you could build the box and just pour the material over the entire bust, and maybe that will still work if I figure out a way to cover the cavity.
Sorry for the sideways pics, I couldn’t rotate them for some reason.