Here\'s how to make a mould and hand cast a mini!
There\'s a company in the UK called Tiranti\'s and they supply all sorts of sculpting materials and tools, some of which is useful to the modeller. They have a number of booklets detailling how to make moulds and casts of models and parts. I must stress that these booklets and all the materials are not aimed at counterfeiters! Just thought I\'d better mention it as there\'s always one!
Anyway, from what I\'ve read, here are the bare basics:
The mould. Cold cure silicone rubber is used to make the mould. There are a number of different types available all with slightly different properties depending on the purpose they\'re intended for. Basically this stuff will cure (set) under normal room temperature. No vulcanising!
Make a box to cast the mould in. Lego or similar seems quite popular. Use a base piece and build up a suitable box like structure. Then using modelling clay (non hardening type) you mask off half of your figure. Basically fill the bottom of the box with clay and press the figure into it. Also add a few studs that stand proud of the clay as these will create your means of registering the two halves of your mould when you come to casting! Mix up your silicone and pour it over the partially masked off figure, filling the box.
Once cured, removed the lego bricks and take out the silicone and clay lump. Remove the clay and clean up the figure (still keeping it in the silicone half). Rebuild the box and put the silicone and figure back in but silicone side down. Spray with some stuff to stop the next lot of silicone sticking to the half already cured, and then pour in more silicone. Voila, a two piece mould!
Next, casting in metal. Cut air vents in the mould to allow the metal to be drawn into all the extremities of the mould.
There are a few different types of metal available: pewter and various tin/lead alloys all with slightly different properties. If hand casting it appears that a metal with a relatively low melting point is best. Heat the metal in a ladle over a gas flame until it melts. Then pour it into your well clamped together mould and hope for the best! Once cooled you\'ve got your figure.
I\'ve never done this myself, but it seems relatively straight forward from the booklets I\'ve read. It is a bit more complex than I make out here though, and does require rather more work than is perhaps evident from my garbled ranting.