Resin casting question

I’m doing my first resin casting, using non-hardening clay, mold builder, and resin casting.

My goal is to produce 7/8n people (nearly 6 inches tall) for my Gauge 1 and O line.

I read an old GRR mag article that discussed cutting up people and repositioning body parts.

Thus, I’m casting heads, legs, arms, torsos separately to mix and match later on.

Right now, I’m working on a head.

I built the head in clay and the 4th layer of mold builder is drying as we speak (plan about 3 more layers).

The head is fixed to a 14 gauge wire, running into the neck and gripped in a vice.

The head has a hat, sort of like an Australian bush hat.

Now, the question. Once I’ve built up the mold, it appears that it would be impossible to pour the resin into the mold and then extract it without breaking the mold, as the hat’s brim sticks out.

I’m thinking of perhaps first cutting the hat off and casting that separate from the head. However, the head too may have problems as the nose might not separate so perhaps cut the head into 2 halves with the face and back of head cast separately?

Advice appreciated as I’m nearing completion.

Thanks.

One way is to add a parting line - basically cut the mold into two pieces, then clamp it back together for pouring. This is usually done be construction the mold in two halves, but in your case, I would try cutting it with a razor saw. This will result in a bit of flash that needs to be cleaned off each part.

Also take a look at these:

http://www.google.com/search?hl=en&lr=&rls=GGLD%2CGGLD%3A2004-13%2CGGLD%3Aen&q=resin+casting