Why don't we all post our casting process in this thread? There are tips and hints in everybody's method.
1. Wash the molds. Place them in a bucket with water and Jet Dry. Cast one more mold than you need, using it to hold extra material.
2. Spread a clean plastic sheet with no holes over a flat work area.
3. Pour cool water into a small bowl. This will make the material set slower and allow bubbles to rise.
4. Shake plaster material into the bowl. Since I use high-density, strong material, I can mix it thin so that it flows into the mold easily with few bubbles.
5. Mix the material with a spoon until no clumps remain.
6. Stir and scoop the bubbles off the top.
7. Remove the molds from the bucket, shake them vigorously and place them on the sheet.
8. Make sure the edge of the bowl is clean and dry for pouring.
9. Gently pour the material in a thin stream on the intersections of the mold, letting it flow into the holes. Only fill half.
10. Wiggle a small, old plastic brush in the pockets to release bubbles.
11. Vibrate the surface.
12. Fill the mold to overflowing.
13. Vibrate the surface again.
14. Tap the top of the molds with a plastic trowel. This shakes the mold a little and breaks surface tension, allowing excess material to flow off.
15. Using a digital kitchen timer, wait 6-15 minutes for the material to start to solidify.
16. Lightly scrape off the water and wet material from the tops of the molds.
17. Wait 30 minutes. If the material is hard, use a paper towel to absorb any extra moisture from the tops of the bricks.
18. Wait 30 minutes. Pick up the molds. Rub the edges to get rid of dried overflow.
19. Hold the mold at an angle and tap it to break off dried excess between the bricks.
20. Remove the pieces from the mold. Place them on trays to air-dry.
21. Place a unique piece in a bowl for a count of the number of casts.
22. Scrape the junk off the plastic sheet into the trash.
23. Wash the tools. Wipe down the work area. Make sure no water or debris got under the sheet.