YouTube video covering last carving and last casting
Note
- foot measurements
- foot tracing
- gave ½″ space ahead of toes
- toe spring and heel lift notes
Carving
-
laminated wood block from pine
- easier with a bandsaw with enough clearance
- handsaw, later table saw
- chisel
- Surform
- “a lot of work”
- “get yourself a bandsaw or some other way of cuttin’ it, ’cuz that was a pain in the ass”
- flap disk on drill to sand
- laminated block from insulation foam
- glued side profiles of last to the blocks
- don’t use spray adhesive that melts foam
- foam saw
- Surform
- glued bottom paper to bottom
- sandpaper
- filled voids with silicone
- cardboard
- cut out profile pieces, then laminated
- spray adhesive
- easiest of all
- foam saw
- Surform
- covered in Mod Podge
- sanded
Casting
Alginate
- used leather pieces to lift heel and toe
- covered foot tracing in duct tape for molding
- plexiglass molding box
- taped the template into the box, put foot on it
- clay over toes to fill out toebox
- alginate for molding
- mix into the water, not the other way around
- poured around the foot
- 15 minutes to cure
- slid the foot out
- turned the mold over and cleaned out the clay
- board on the bottom of the mold to prevent expansion
- Foam-It! 5
- release agent
- expanded 10 times
- cut away flashing, sand down
- foam over-expanded in some places
- wood filler over the surface
- coated with Mod Podge
Plaster
- plaster bandage
- cut into small squares
- cut with scissors down back
- covered cut with more plaster
- pancake batter consistency
- poured into mold
- cut and ripped the original bandages away
- built up toebox with clay
- covered the entire thing with clay
- plastered over the new form with plaster paper
- broke in two halves
- Foam-It! again
Old Shoe
- by far the easiest
- covered old zip boot with duct tape to hold quarters down
- tape on inside to smooth out
- Foam-It! again
- cut the shoe to release the foam
- will use the cut shoe as a pattern
- forming foam clay to fill gaps