Step 2.1: Remove Cast1-groove cover and excess silicone
After the first cast is cured, remove the Cast1-groove mold piece by slowly lifting the handle.
There may be air bubbles in the cast silicone but it is not a problem since they can get filled in the second cast.
Cut or peel off excess silicone so there is a smooth channel for the wires.
Step 2.2: Insert the wires
In the Base mold, there are two notches on the sides of the wall. One notch is centered on the swab, and the other indicates where the exposed wire should begin.
Insert the wires into the two mold channels and line up the bare ends with that notch. Press the wires all the way into the channels. If the wires do not lay flat, try rotating the wire or take it out and straighten it until it lays flat.
Step 2.3: Prepare the grease syringe
Wear vinyl or latex gloves. Collect the 10 ml syringe and the Carbon Conductive Grease Tube.
Open the tube and insert the point of the syringe deep into the tube.
Pull the syringe back (it will most likely resist and try to return back to a relaxed state).
Hold the syringe in the pulled back position for several seconds to pull grease into the syringe.
It may be necessary to trim the tip of the syringe to make the opening bigger.
Step 2.4: Insert grease into grooves
Practice applying the grease in a smooth even line on a paper towel. Slowly push the plunger while moving the syringe away from the dispensed grease.
When ready, carefully insert the point of the syringe into the U-shaped channel in the silicone. Slowly push the plunger while moving the syringe throughout the channel to fill the channel completely with grease. The grease should be at least level with the height of the channel. If the wires poke up while spreading the grease, simply push them back down with the nose of the syringe.
Make sure the entire exposed part of the wire is fully covered in grease. Use a wood stick to remove any excess grease that is higher than the channel. The grease should be as level as possible with the silicone rubber.
Step 2.5: Repeat Step 1.3: Measure and mix Ecoflex 00-30 silicone rubber
Repeat Step 1.3: Measure and mix Ecoflex 00-30 silicone rubber
Step 2.6: Pour silicone into the Base mold, over grease and wires
Collect the Base with the silicone, wires, and grease, the Cast2-top mold, and a paper towel.
Lay a paper towel on a flat surface and place the Base on top.
Pour silicone up to the second cast level/step in the Base mold. Overfilling is okay since the excess silicone will be pushed out by the Cast2-top piece.
Step 2.7: Place the Cast2-top mold piece on the Base mold
Place the Cast2-top mold piece on top of the Base mold, and align it.
Apply light pressure on the mold piece to push any excess silicone out of the Base mold.
Leave the assembly in a well-ventilated area for four hours to let the silicone fully cure.
Step 2.8: Remove the Cast2-top cover
Remove the Cast2-top mold piece by slowly prying up the edges. It may take a minute or two since the silicone will stick to the top mold piece. There may be a couple of air bubbles – this is not a problem unless the bubble is exposing the grease. In that case, simply fill it once more with a little bit of silicone to cover up the bubble, and let it cure.
Step 2.9: Extract the whisker assembly and remove excess silicone
Once the silicone is ready to remove, slowly peel up the edges of the silicone rubber and pull upward. After a bit of peeling, the whisker assembly should come free out of the Base mold. If it is very difficult, use a utility or craft knife to cut along the edges of the silicone rubber base. Lift the whisker assembly out of the base mold. Use scissors to trim any excess silicone along the edges and near the wires.