How to Make a Rubber Hatchet (Theater Props, Cosplay)

Learn how to make a rubber hatchet using ComposiMold and Silicone.

Clean the Hatchet

Clean the hatchet using soap and water. Remove any dirt, dust, loose paint and rust.

Embed the Hatchet Into Clay

Embed the hatchet into clay so that half the hatchet is showing then create Key holes (indents) in the clay.

The key holes help the two mold halves line up.

Coat the Hatchet With Mold Release

Mold release will help keep the ComposiMold from sticking to the hatchet.

Brush ComposiMold Onto the Hatchet

Start with a thin layer of ComposiMold and continue to brush more layers as the ComposiMold cools and thickens. The mold should be at least 1/4 inch thick.

Create the Mother Mold

Once the ComposiMold has solidified, mix a batch of plaster of Paris.

Soak cheesecloth into the Plaster of Paris, and place at least 5 even layers of the Plaster soaked cheese cloth onto the rubber ComposiMold mold.

De-mold.

Once the Plaster has hardened it is time to de mold (The Plaster will harden after 3 hours). Remove the clay and the hatchet from the mold.

Clean up the hatchet and the mold to prepare them for the second half of the mold.

Create Keys in the Mother Mold

Create keys in the mother mold so that the two halves fit together perfectly.

I used nuts in this example and glued them down with plaster. This will create holes in the second half allowing them to line up correctly.

Create the Second Half of the Mold.

Once the mold and hatchet are cleaned put them back together.

Coat the hatchet and mold with mold release, then brush on the ComposiMold. Make sure to chill the first half in the fridge or freezer for an hour before brushing on the ComposiMold. Also, make sure the melted ComposiMold is below 145 Fahrenheit before brushing it on.

If these steps are not followed it is possible for the two halves to melt into each other.

Create the Second Half Mother Mold

Lay saran wrap over the mold so that the Plaster doesn't stick to itself.

Then do the same thing we did to create the first half of the mother mold.

De-Mold

De-Mold once again removing the hatchet from the mold.

Prepare the Mold for Casting

When casting with silicone you can paint the mold with resin dyes or oil based paints.

Prepare the Silicone

Dye the silicone using resin dyes or oil based paint, then brush it onto the mold.

Finnish Casting

Quickly put the two halves tightly together, then top the mold off with more silicone.

De-Mold and Clean Up

De-Mold the rubber hatchet (the silicone took 16 hours to cure) Clean off any extra paint.

Enjoy! Use it as a stage prop, for Cosplay, or for pranking your friends.