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Paper machè horns.

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The aim here is to make a horn loaded bookshelf speaker for a shed system. Basically a mini version of my main system....a41a402265b16bf5060f5a3666d3055c.jpg
Some of you may remember my failed attempt in the DIY thread. Basically i made a plaster mold....cf89bf3efad4a315015f860664d609d5.jpg
This is the painted and polished mold. I layed the wet paper on...d849fe4c0ae30b622d3c4f1a99043277.jpg3e929285edac7114e348f76211007e5c.jpga1c7b0b0c91f0da633c90fb532387827.jpg4b4ada571fabc0d4bc1ab2b25e6a49b3.jpgand built up layers to about 10mm in thickness. This seemed to go really well until I left it to dry. The paper machè shrunk and cracked the plaster mold. It was so tight I was unable to remove the horn. So in the bin it went and not to be beaten by effectively wet paper, this is take 2. The silicone version.
 
To start i needed a stand to hold thr frame5b6562ba7558767e85cdb70c9be2547d.jpgf3c9c3360961b37ac2382a46f7a9bfd9.jpg08060f883e49ebf2b1690f90da1bbd28.jpgfc9de47e2d00d677e611a73f22fbdb3d.jpg885aa60b6e38f460530b734b6342b229.jpg
Also made a plug to, use less silicone and make removal easier.
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a073c501b797525501ccc29fd0b354a5.jpg
 


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Needs more beer.....................waits for the next instalment.

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When I do cement ones, I use cooking oil.

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Good on you.
 
John Inlow says you need Vaseline or similar product to avoid the paper from pulling on the mould.
 
http://inlowsound.weebly.com/diy-paper-mache-horn.html

I used large amounts of dish soap. I was worried that the vasoline would stain the paper. Live and learn! The new silicone mold wont have that drama and now goes down to a 1" throat rather than 50mm like the last one. So it will be a lot more versatile than the last one.
e2641de828acffcf93d0d893dc0799d1.jpg8ea5845f3b940adeb22d4ab6907bd238.jpg I used rice to measure the volume to make sure I have enought silicone. Turns out I don't. I bought 2kg of silicone. Turns out its only 1700ml. A good thing I measured!

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Plasticine to seal the edge between the edge of the horn and the rest of the mold. Then polished the entire mold. So far the very basic mold has cost me 10 bucks for the plasticine..... and 300 odd bucks in silicone.3ac3df1678fc08a00c91b10ed7aebb20.jpgf74172e0db40be0b3bc7a12527294d47.jpga2e2b9ee0bc57a0ec11857af2a45c28d.jpg15812f921e7dc72bde0175314d2bb59e.jpg9d975d56406e4fdc455b5be308d838cf.jpg4e0cec6808e7b25d1dd748e18902fc33.jpg161ef3939ff22f468809e1c50ed6ab32.jpg81ee9b6f9b69e98f0b8dc046c55f4f7f.jpg

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7efb3287aa7a5112117ad69b0a9d155e.jpgb5cf4818550d057dedfc79273b62c9df.jpg0339a21f2aaef3e25169e9b6b5c65c7d.jpgd05899e9d8843007e21a3b3c2cf0d01d.jpg34d5dece7e68451758d359163fc05431.jpg
Sphincter puckering moment... needed the dutch courage! Hoping it works. Between the horns, painting the horns, and silicone it could well be an expencive mistake!

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When I do cement ones, I use cooking oil.

Any photos of the cement ones mate?

Sent from my SM-G900I using Tapatalk

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1 hour ago, Upfront said:


Any photos of the cement ones mate?

Sent from my SM-G900I using Tapatalk
 

 

I wasn't making horns, they were paving moulds!

(I did think about it though.........)

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I note that the alcohol has gone from beer to rum to cope with the extra sphincter puckeringness too!

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I wasn't making horns, they were paving moulds!
(I did think about it though.........)

You have me thinking now too!

Sent from my SM-G900I using Tapatalk

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I note that the alcohol has gone from beer to rum to cope with the extra sphincter puckeringness too!

Yep. With some coal, I could have made diamonds.

Sent from my SM-G900I using Tapatalk

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1 minute ago, Upfront said:


You have me thinking now too!

Sent from my SM-G900I using Tapatalk
 

 

I was thinking lightweight stuff..............although, that can be shaped with a router.

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I was thinking lightweight stuff..............although, that can be shaped with a router.

Hebel. An interesting idea!

Sent from my SM-G900I using Tapatalk

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Looks to have set. They tell me that it takes roughly 1h to set. But this is Hobart. Its 5° outsite. So will leave it for the night and hope like hell it all comes out ok. Fingers crossed.14faa80352ba54d16cbf0d2931de284f.jpg

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Try alginate for mould making. Sets fast and is easy to use and picks up every little detail.

 

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Try alginate for mould making. Sets fast and is easy to use and picks up every little detail.
 

Is it reusable? As in, could i use the mold more than once? Where is it available in reasonable quantities?

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Not sure if you could reuse it but if latex only took an hour to dry them possibly yes.
https://www.amcsupplies.com.au/index.php?main_page=index&cPath=2026_2723_2206
Ive used it to make casts of the kids hands when they were little. You can see their finger prints etc, it picks up every little detail.

Certainly cheaper. I used the silicone because of its durability. The idea is to be able to make multiple horns off the mold. The alginate looks brilliant for one off. Looks like i need to do some research! Thanks mate.

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Was there a reason you didn't make the mold plug using fiberglass as is usually the case?

 

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Was there a reason you didn't make the mold plug using fiberglass as is usually the case?
 

I didnt want to damage the original horn basically. I looked for lowest impact to the original and reusability. I wasnt sure how with fibreglass I could protect the original.

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Normally you just polish hell out of them with mold wax and then apply a (latex?) release agent before glassing. The horns tapered profile would make release of the plug quite easy. The original horn would clean up back to as-new.

 

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Normally you just polish hell out of them with mold wax and then apply a (latex?) release agent before glassing. The horns tapered profile would make release of the plug quite easy. The original horn would clean up back to as-new.
 

I'm hoping I've done enough polishing for the silicone to come off nicely.

Sent from my SM-G900I using Tapatalk

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Posted (edited)

Did someone mention sphincter puckering? :wacko:

 

Nice take 2 Linc. Looks well thought out.

 

And good to see a use for those old pottery tools. 

Edited by shaky

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