WARNING! HOT WAX MAY CAUSE BURNS TO EYES AND SKIN. Always use appropriate protective equipment when handling hot wax (closed-toe shoes, gloves, aprons, face shield, etc.)
Wax melts at 170ºF, and will ignite at 347ºF. If it ignites, remove source of heat and, if necessary, extinguish flames with CO2, dry chemical or foam. Do not use water, as this may spread flames!!!
Skin contact: Submerge injured area in cold water. Leave wax in place, rather than pulling away damaged skin-cool wax will protect skin. Seek treatment, if necessary. Avoid inhalation of fumes: Always provide adequate ventilation., and/or a NIOSH certified organic vapor respirator with a dust and mist filter. Do not ingest: If ingested, do not induce vomiting. Health Center ph#: 479-6435
Always put on a face shield marked "WAX," and cover your arms, legs and feet. There are gloves and other wax tools in the nearby drawers. Turn on the overhead vent. There are two wax pots in the foundry. One is kept at a 'general purpose' temperature, about 180ºF. The other is kept a lot hotter, about 250ºF, and is used for recycling wax and melting wax off of tools. Use extra caution when using this hot wax. Use a striker to light the burners underneath the wax pots. The wax will melt in about 30-60 minutes or so. Prepare the slate table with a layer of water, to make clean-up easier. Turn off the wax pot when you are finished. Always clean up your mess, and return the tools in better shape than you found them. Always separate wet or dirty wax for recycling. Keep water out of wax pots!
Begin by making a sheet of wax. Soak the plaster bat with water until it is saturated; sponge away standing water. Pour a large ladle of wax over the bat until the wax is 3/16 inch thick. Allow to cool, and remove. The sheet may be manipulated by hand, with tools, cut-and-darted, etc. It will be easier to work if warmed by the sun, a hot-air gun, heat lamp, warm water, etc. To add one piece of wax to another, warm the wax and firmly press pieces together, or use a soldering iron or hot knife to melt pieces together. Avoid inhaling fumes. Warm wax is fragile, so allow welds to cool before moving. Any image thicker than 1 inch must be kept hollow, be sturdy and of consistent thickness.
PREPARING THE MOLD: Always use an appropriate parting agent before casting wax in mold:
CASTING WAX: Small molds may be filled with wax and left to cool for 15-30 minutes, depending on size, then de-molded. Larger molds may need to be partially filled, gently 'slushed' and thoroughly rotated while being emptied. Repeat this process until of consistent thickness is achieved-the ideal thickness for most projects is 3/16 inch, which is between 1/8-1/4 inch. Hot wax may also be brushed onto an open mold or onto a wax pattern in order to add thickness.
To get the best wax impression from a rubber mold: