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Poly is available in qualities that can be cast, locate a dealer for that. Find out which hardness you need. Then build your molds while considering the shrinkage factor of your chosen material. Access to a lathe is very helpful here. Figure out where to divide the mold to be able to get your finished piece out. Track down a vac pump to be able to get all the bubbles out when you've mixed your batch. Fill up you mold, wait for the poly to set. Open your mold, cross your fingers and check the dimensions of the finished cast.
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