From left to right, The first pic is the door I needed to make, Pic2 is my first attempt to create a mold using modeling clay to Jig up the model, that mold was 2 pieces the mold worked but wore out early. Pic3 is step 1 in building a 3 piece mold, Pic4 is step 2 adding the gate and vents, Pic5 way and mix the silicone. First pic is the silicone in the vacuum chamber to DE-gas it. The vacuum causes the gases that get mixed in during the mixing of the two parts of the silicone to boil out, or your finished mold will have air pockets in it. Pic2 is a close up,pic3 is the assembled mold, pic4 is the bottom removed, pic5 is the outer ring removed pic6 is the mold all opened up, the model has been removed and the mold is ready to be reassembled and used. On the left is the door I made. On right is the IBM door. My door only needs to be screen-printed, with the mic, head, video icons. The color appears off in the pic, but it is very close, the camera makes the color look worse than it is, the IBM door is old and not as shiny. The chemicals to make the doors are from Freeman supply co. and are a two part urethane compound. 3.5 Grams of each part A and B or a 50/50 mix, are enough to fill the mold The construction of this mold took 18 Hrs. and the mold produced about 125 doors before it wore out and a new one had to be made. more soon