Making Molds for the Empty Room

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Making molds for the house that will be used in our upcoming film, The Empty Room, has been the major focus of the last few weeks.  Using the preliminary drawings and the scale model discussed in the last post, Gabe focused on drawing the transfers.  These are done on trace paper, using a soft lead and a light table designed and made by Gabe.

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Each of the transfer pages is an exact map of the clay tile that will be built.  The light table is necessary so the transfers are not backward when they are placed on to the clay slab.

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The trace paper is laid, graphite down, onto the clay surface and smoothed out.  The paper begins to wrinkle and distort almost immediately so this step must be done quickly and precisely.  Once the sheet has had full contact with the clay and is lightly compressed onto the surface, the paper is removed and the clay is ready to work.

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The first step was to trim the borders of the wall.

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Next, the masonry joints were pushed into the slab along lines indicated by the transfer sheet using a custom rib that Gabe made for the purpose.  These lines needed to be exactly the correct size and completely uniform, no tool we had, was able to give exactly what we were looking for, so making the tool was necessary.

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Once the tile was completed, clay walls were built in preparation for plaster casting.  Shrinkage was a major factor as we need the closest size uniformity possible among the tile molds so each of them was cast no more that 12 to 18 hours after they were made.

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Using the paster formula from ceramicartsdaily.org, the tiles were cast.

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We ignored the 1″ border that is conventional in mold making so the tiles could be cut exactly to size, using the mold itself as a guide.  This makes the molds extremely fragile, we are using great care in storage and drying.

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Each wall needed its own mold because of the intricacy of the brick detail which is correct for structural brick.   In addition to the brick pattern, the third floor has many architectural details and each of the panels needed a full redesign.  At this point we have 13 molds completed with many internal details to continue to resolve, but it is encouraging to see the project so well on its way.

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