- 1). Draw a pattern for the size and shape of your doll parts. Roll some clay into flat shapes to match the doll parts. Decide the thickness of the part and add clay to make a finished sculpture of each. Do not join the parts into one, since a mold will be made for each individual part. Design the sculptures so ball joints and elastic can fit inside by leaving the forms hollowed out. Sculpt balls for the shoulders, knees, elbows and pelvis that can fit into the hollows. Fire the sculptures in a kiln, if necessary, to finish.
- 2). Create a containment field to hold your sculpture and mold rubber around it. Nail pieces of wood together into a rectangular shape to contain the sculpture. Nail a baseboard into the bottom of the box. Use a silicone caulking gun to secure the edges of the containment field so that rubber will not escape.
- 3). Attach the sculpture inside the box to the baseboard with the silicone caulking gun. This prevents the sculpture from moving while the mold dries. Paint the sculpture with a sealing agent like shellac to prevent rubber from seeping into it. Purchase a release agent and apply it to the sculpture and inside of the containment field. Release agents usually come in aerosol cans and can be sprayed on, but they also are available in liquid form. Apply either type lightly. This allows the mold to be easily removed from the containment field and sculpture when completed.
- 4). Measure the mold rubber and mix it according to the directions on the product packaging. Follow the directions exactly to get a proper mold. Pour the mixed mold rubber into the containment field and around the sculpture at first. Pour at a constant rate and gradually cover the sculpture. When fully covered, allow the mold rubber to dry at least 16 hours. Once dry, carefully remove the mold for reproduction.
- 5). Pour silicone into the finished mold to create replicas of each doll part. Attach S-hooks inside the wrists, ankles, and head by caulking them into the hollowed areas at the end of each part.
Wrap elastic around the hooks and run it inside the hollow body parts. Run a line of elastic from one wrist to the other by crossing through the torso. Run two other lines up from the hooks in the ankles to the hook in the head. All elastic should be hidden from view when finished.
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