Create a New Leg
Text and photos by Jennifer Danza
We will be creating a simple two-part mold in order to create a new leg for this Traditional Quarter Horse Yearling.
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| Broken Model |
The first step is to stand the horse on cardboard by making a brace for the broken leg using non-drying clay like Chavant. Place a few wads of clay around the other hooves as well to hold the horse securely in place. Also, be sure to place a cylindrical shape under the hoof you will be casting. This extra wad will serve as a "pour" hole later.
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| Supports and pour hole added |
Lesli Kathman of Blackberry Studios http://horsecolor.info introduced me to the use of LEGO® blocks as a mold making material and every time I use these blocks, I have a successful casting session. For this model, the other front leg is similar to the missing leg so I chose that one to cast. Slowly start to build a rectangular shape around the good leg using the LEGO® blocks.
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| Begin to add the blocks |
Continue building up the blocks until they reach the area above the break. Then, swab a thin coat of Murphy's Oil soap or Vaseline on the inside of the mold and leg. This will keep the liquid rubber from sticking to the box and leg.
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| Add Murphy's Oil |
There are many different liquid rubbers on the market. I have used a few and found OOMOO 25 liquid rubber compound by Smooth-On to be extremely easy to use because it's used in a 1:1 ratio and dries within 75 minutes.
SAFETY NOTE: BE SURE TO WEAR YOUR RUBBER GLOVES AT ALL TIMES!
Take two paper cups and pour liquid from the OOMOO 25 Part A in one cup and the same amount of liquid rubber from Part B in the second cup. Then, pour one cup of liquid in the other and stir until it is thoroughly mixed. That should take about a minute.
Slowly pour the mixed rubber into the mold box. Pour from one of the corners.
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| Pour liquid rubber from corner of mold |
Let the mold sit and cure for the recommended times. I normally wait a day.
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| Mold filled with liquid rubber |
Break apart the mold box to reveal a block of cured rubber around your horse's leg.
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| Cured rubber |
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| Disassemble the blocks |
Carefully cut the sides of the rubber block with an X-Acto® Knife. Pull the mold apart to reveal a negative impression of a hoof and leg.
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| Mold cut in half to reveal impression |
Put the two mold pieces back and hold together with a rubber band with the pour hole facing up. If there is a hole on the other end plug it up with some Chavant.
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| Mold securely closed and ready for resin |
Mix liquid resin according to manufacturer's directions. I prefer a 1:1 ratio liquid resin like the resin sold by Freeman Manufacturing & Supply Company called Hobby Cast 100. It's very easy to use and cures in about 15 minutes.
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| Cured resin in mold |
After the new resin leg has cured take it out of the mold and attach it to the broken leg using Zap a Gap® glue. Add a bit around the entire leg break. To make this extra glue harden instantly sprinkle on a tiny bit of baking soda.
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| Glue new resin leg to broken stump using Zap A Gap® Glue |
To further strengthen the leg, apply a small amount of Aves Apoxie around the entire breaking point and smooth it out. Let this epoxy dry for 24 hours.
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| Epoxy area for extra strength |
Prime only the epoxy areas and then touch up the broken spot with paint.
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| Close up of the new leg |
For this horse, I left the natural color of the resin unpainted where the sock would lie. I felt the natural look of the resin matched the look of the Breyer plastic socks perfectly.
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| Looking good! |
HOT LINKS:
Sample pack of liquid rubber: www.smooth-on.com
Liquid resin: www.hobbycast.net (they also sell rubber)
Epoxy: www.avesstudio.com
TIP: Using paper cups will allow you to see through the cups and eyeball your 1:1 measurements.
SUPPLY LIST:
Chavant non drying clay
LEGO blocks
Murphy's Oil Soap or Vaseline
OOMOO 25 Liquid Rubber
Paper drinking cups
Xacto knife
Hobby Cast 100 polyurethane resin (or similar resin brand)
Zap A Gap® Glue (or Crazy Glue)
Aves Apoxie
Acrylic paint
To learn more about Jennifer Danza and her artwork, please visit www.jenndanza.com!
