Small Climbing Wall
by hyman.stewart in Workshop > Molds & Casting
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Small Climbing Wall
![IMG_1548.JPG](/proxy/?url=https://content.instructables.com/FHH/7JN8/K1QRUHZF/FHH7JN8K1QRUHZF.jpg&filename=IMG_1548.JPG)
For this project, I will be taking you through the process of the construction of the climbing wall.
Supplies
Materials Needed:
Foam, Exacto knife, Polymer clay, Silicon mixture, Choice of wood, Plastic resin, hot glue, Power tools: hand drill, dremel, sander Paint
Cover the Foam Model
![IMG_1376.JPG](/proxy/?url=https://content.instructables.com/FOF/VV5I/K1OE8UIG/FOFVV5IK1OE8UIG.jpg&filename=IMG_1376.JPG)
![IMG_1374.JPG](/proxy/?url=https://content.instructables.com/FWT/G31C/K1OE8UID/FWTG31CK1OE8UID.jpg&filename=IMG_1374.JPG)
Constructing the holds.
In this step, I took foam core and cut it down to resemble a shape that can be used in multiple ways and angles. The shape that I went for has many different options for hand holds, foot holds, and finger holds.
Thinly roll out a piece of clay. I used polymer clay because it is safe to set in the silicon mold. Other types of clay may also work. I covered all of the cracks with more clay so that no silicon would seep into the cracks and create extra holes.
Create Foam Box
![IMG_1389.JPG](/proxy/?url=https://content.instructables.com/FDI/6CUC/K1OE8UII/FDI6CUCK1OE8UII.jpg&filename=IMG_1389.JPG)
With a lazor cutter or an exacto knife, cut a box out of foam core. I used a knife with layers of hot glue.
Fill the Box
![IMG_1390.JPG](/proxy/?url=https://content.instructables.com/FAM/M3ZD/K1OE8UIJ/FAMM3ZDK1OE8UIJ.jpg&filename=IMG_1390.JPG)
In this step, I put the model in the box. I had to use skewers to hold it down so that it would not float up when the mixture was poured over top. I then poured the silicon mixture on top and waited for it to set. This process took 30 minutes.
Cut the Mold
![IMG_1395.JPG](/proxy/?url=https://content.instructables.com/F13/UUDY/K1OE8UIK/F13UUDYK1OE8UIK.jpg&filename=IMG_1395.JPG)
After the mold set, I used an exacto knife to carefully cut the mold in half. For this step, I used an extra set of hands to pry the mold open as I cut it open.
Pour the Resin
![IMG_1398.JPG](/proxy/?url=https://content.instructables.com/FRN/COY3/K1OE8UIL/FRNCOY3K1OE8UIL.jpg&filename=IMG_1398.JPG)
I used rubber bands to hold the cut open silicon mold. I then mixed the plastic resin mixture and poured it in the mold. After this, I waited 15 minutes for it to set.
Alter the Hold
![IMG_1399.JPG](/proxy/?url=https://content.instructables.com/F47/YMSZ/K1OE8UNB/F47YMSZK1OE8UNB.jpg&filename=IMG_1399.JPG)
When the plastic hold comes out of the mold I sanded it and made alterations. This was the finished product of the first hold. It has many different hand placement options.
Replicate Holds
![IMG_1432.JPG](/proxy/?url=https://content.instructables.com/F5G/P4P5/K1OE8UNC/F5GP4P5K1OE8UNC.jpg&filename=IMG_1432.JPG)
I decided to cut the remaining two holds into separate pieces which could act as smaller holds. I then sanded them down.
Attach the Holds
![IMG_1472.JPG](/proxy/?url=https://content.instructables.com/F9Y/ZUB2/K1OE8UIM/F9YZUB2K1OE8UIM.jpg&filename=IMG_1472.JPG)
I drilled holes in each of the holds with different sized for the bigger and smaller ones. I then attached them to the wall.
The Unfinished Project
![IMG_1474.JPG](/proxy/?url=https://content.instructables.com/F9Q/ID4E/K1OE8UIN/F9QID4EK1OE8UIN.jpg&filename=IMG_1474.JPG)
I tried many different ideas such as creating a peg bored and an overhang. Neither of these worked, but I did add two more panels so extend the shape of the wall.
Cut Bolts
![IMG_1476.JPG](/proxy/?url=https://content.instructables.com/FY4/8AR6/K1OE8UIP/FY48AR6K1OE8UIP.jpg&filename=IMG_1476.JPG)
To touch the wall up and make it hangable, I used a dremel to cut the back of the bolts off.
Paint
![IMG_1479.JPG](/proxy/?url=https://content.instructables.com/FX8/FT4Y/K1OE8UIQ/FX8FT4YK1OE8UIQ.jpg&filename=IMG_1479.JPG)
I decided to paint the wall mainly white with hints of purple and red. After this, I let it dry and sanded it down slightly.
Hang
![IMG_1548.JPG](/proxy/?url=https://content.instructables.com/FKS/7IMQ/K1QRUGYY/FKS7IMQK1QRUGYY.jpg&filename=IMG_1548.JPG)
We used six screws to drill the wall to another wall. It was then time to test it.