A plaster jacket is made after 5 coats of rubber are applied to the clay model. Next, the mold is "popped", the clay model is removed and the mold is taken to the foundry. The rigid plaster holds the rubber mold in place while liquid wax is poured into the mold. Shown below is the wax replica of the cougar after the wax cools and it is removed from the mold. The hollow wax casting is identical to the original clay model.
Next, the wax replica is cleaned up or "chased" . . . meaning all imperfections, flashing, shim lines, pits and bubbles are repaired. Shown below is the wax chaser cleaning up the wax model with a hot iron.
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