So yesterday I got the rubber compound to make my mold. When I got home I realised that I had no dish big enough to fit the coil in to pour the rubber around. I was going to have to make something. I got some hardboard and duct tape and eventually made a container that was the right size to hold my wooden form.
Mixing the hardener into the rubber glue stuff was a bit of a nightmare. It is messy and sticky, and you can be sure that you are going to throw anything away that you used to do the mixing. I eventually got it done, poured the stuff, and then realised that I might not have enough to cover the form. Jonty, my son in law, came up with the idea of sticking stuff into the rubber to try and displace some of it, making the lever rise. We had toilet roll inners, so we covered the one end with tape and stuck them in.
This morning everything was hard, so we took it all apart. The mold came out great!! I just have to trim and clean it slightly, but otherwise it looks good. Now all I have to do is actually make my coil using the epoxy. I might coat the mold with a bit of vaseline before I pour it, just to make sure nothing sticks too tight and I can get the coil out of the mold.