The first step was to construct a model to make the mold from. The measurements of the original were scaled down to 75% to make it more practical as a bar of soap. Wood was used for the bulk of the model, and the detailing on the face were added to that. The block of wood was cut to size and then passed through a table saw set at a 17 degree angle several times to make the beveled sides.
The design on the front of the bar was sourced from the internet with some changes made to reflect accuracy to screencaps from the episode. The image was printed to card stock twice, one with the first layer cutouts made, and the second on top of that to complete the image. Double sided tape was used to adhere them to the wood block.
The model was then sprayed with lacquer primer to seal it. This also helped to highlight areas that needed some work, mainly chips in the sides and along the wood to card stock transition.
Red spot putty was used to fill problem areas, and sanded down smooth using 1000 grit sandpaper and water.
The model was then sprayed with one more coat of primer, before being sprayed with flat black paint to give the whole thing an even matte finish. The finish texture is important because it will transfer over to the mold.
After we finally have our piece to mold from, it is then on to color matching, formula testing, fragrance development, product descriptions and photography. SO WORTH IT!
We would love to hear what you think in the comments below! You can find our brand new Alliance Soap Bar right here! ♥♥♥
