After working on the Aggro Crag Keychain for over five years, I designed and prototyped a six inch version. This process of building a working prototype kept getting shelved to make time for other projects and was stretched out over three years.
Creating the Pattern
In order to create a silicone mold to cast resin into, I needed to create a pattern. Patterns can be made using just about anything that is dry and oil/dirt free, including, but not limited to, clay, plastic, epoxy, wax, paper mache, plaster, etc. For the 2″ key chain replica, I used 100% wax, but in this case, I went with a combination of wax and various densities of foam.
I experimented with a few different techniques to create the texture. One attempt involved heating textured glass and pressing into the wax pattern.
Bondo was another failed attempt to create a crag-like texture.
Finally, I used an acrylic gel coat and the result was a glossy, textured surface.
I wrapped 1/8″ wax around the base so I could make a cut-out for the Guts labels.
I made a simple mold box with some foam board and a glue gun. To do this I scored the foam and gently cracked it down the straight edge of a table or bench. This gives you a seamless 90 angle without having to re-attach the pieces with glue or tape. This box will contain the liquid silicone as it’s curing around pattern.
I cast the silicone mold out of Hapsil 360 tin based silicone from Hapco. This is the only silicone I’ve found that does not inhibit the cure of clear urethane rubbers like the ones I plan on using to create the part.
Update 5/16: I have started prepping the mold to cast the 2nd half. I used foam and clay to form the inner cavity and then cast more silicone on over it to form the 2nd half of the mold.
I added some straws to act as the vents and gates once the silicone is cured. I sprayed the bottom half with Hapco’s Grease-It 5 release agent and build a dam with tape to contain the silicone. Normally, I would build a foam frame around the piece, but I was in a rush.
Update 6/5/14: I painted the inside of this prototype and I’m less than thrilled with the result. The clear urethane is a little too clear compared to the prop from the show and the inner core is not what I had pictured in my head.
Update 8/4/15: It’s been over a year since I made the first prototype and I decided to make a few changes and re-cast this piece.
I used the prototype mold, however I decided to make a few modifications.
With the old top half of the mold re-sculpted in clay, I joined the two mold halves and taped the mold shut. I also rubber banded two aluminum plates on the outside of the mold to keep it from warping while the urethane cures under pressure(75 PSI).
I filled the mold using a Rapidshot meter-mix dispensing gun. I mixed 350 grams of Hapflex 791 part A and 52.5 grams of 791 part B and poured into an empty 400 ml cartridge. After shooting into the mold until the material came out of the vents, I placed the mold inside an X-20 pressure chamber and pressurized at 80 PSI. This was the result:
After removing the part from the mold. I removed the clay and the set the part back into the mold. I sprayed release agent onto the silicone and the part. I mixed a few hundred grams of Hapsil 360 silicone and then vacuum degassed the material. I then poured the silicone into the mold and let cure overnight.
I cast the base out of a rigid urethane that is pigmented black and used epoxy to bond the two pieces together. Unfortunately, I didn’t take any pictures during the process of making the base.
Update 8/16/15: Last week I filled the first order for a personalized 6″ Aggro Crag replica. To purchase this item, please visit my online store at: http://www.blueyestudios.com
Hey I’ve been looking for a way to get my hands on this aggro crag thing for a friend of mine. so much that i want one myself. I stumbled on to your page and was wondering if you were still makiung these and would be willing to sell one maybe two. thank you and have a great night,,,,
Jonathan
Jonathan,
Due to the response regarding the pieces I’ve already made, I am re-making the mold for the larger 6″ replica so that I can start selling them. I will notify you and anyone else who has commented here or sent me emails as soon as I finish. thanks for stopping by!
Best regards,
Dan
Just came across your page, been wanting this since I’m a kid. Are you still making them, if so… how much?
Still making them! You can purchase on my website at http://www.blueyestudios.com
Love the item, looks great. Just wondering what you’re looking to sell them for, would love to own one
Still working on new mold. I will come up with a very reasonable price for anyone who posted a comment here. I put the small one on ebay a few times for a buck and they ended up going for 50-70. I’m excited to finish this 6″ version i think it will make a great collectible.
Yes, this is great! Been catching old episodes on nickreboot, funny being a couch guts champion all over again. XD
Ha! Yes…*licks cheeto cheese off fingers* “I could totally beat those kids”! Every. single. time.
Love this! I am 100% interested in purchasing one if you are still making them. Please let me know when you are done making them!
Thanks,
Tina
Tina,
Thanks for the interest! I have been devoting a solid chunk of time to this. Hopefully I can have a finished product to post on here in May and I’ll see if people want me to make them one. Haven’t figured out a cost but I will eventually.
Best regards,
Dan
Please let me know when these are available. Must have a piece of the Aggro Crag!
I will definitely let everyone on this thread know once I finish. I apologize for this taking so long…I had a mishap with the pattern that is pictured above. Being a perfectionist sucks sometimes.
Best regards,
Dan
I am definitely interested in the 6″ version. Please let me know when these are available to purchase because I will totally buy one!
Thanks!
Buyers will start at the sound of my whistle.
It’s me Mo, I am also interested in purchasing the 6″.
D-d-d-do you have it available yet?
Thanks,
Mo
Hahahaha too funny! BTW I had a huge crush on you when I was younger. That accent and the way you blew that whistle…oh yes. I have the new pattern done as I type this. I updated this post with a picture of it.
Cheers mate!
Dan
I definitely would be interested in purchasing the 6″ version! Let me know when it’s ready for sale, please!
I am definitely interested when they are available again!
I would definitely be interested when available again!
If you are making Replicas I will certainly purchase a few off of you. Please contact me when/if you ever are ready to sell any.
I am buying my first apartment. I need this. You don’t understand.. I NEED this as the centerpiece of my entire life!! Make my nostalgic dreams come true man, I’ll pay ya anything! Please let me know!!!
Hey Mike,
I definitely understand your burning desire for the radical rock. Now that the Northwestern project is done I can get back to this. Thanks for the feedback I really appreciate it.
Best,
Dan
Best,
Dan
Please let me know if these are for sale yet!!!
I will certainly let you know. I lost a month from this project because Northwestern University commissioned me to make an award for them. I will be able to get back to it now.
Best,
Dan
I am interested in one if you are making them for Halloween this year. Let me know.
Thanks!
Erica,
Email me at dan@blueyestudios.com and let’s discuss this.
Thanks!
Dan
Hi,
Please let me know when you start selling these! My husband is the absolute hardest person to buy for, but this.. THIS WOULD BE FREAKIN’ AMAZING!!! There’s no way he couldnt love it right?! haha
So PLEASE PLEASE let know when you start selling them!
Thanks so much,
Summer
Hey Dan! How’s the progress on the Aggro Crag trophies? I’d love to order one when they are available! Do you have a standard price for them??
thanks!
Mandy
You’re so awesome for making these. I’ve always wanted one and I’m really interested in buying one when they’re ready.
Hey Dan, super cool replica! Would love to purchase one for my man cave! Send me the details if possible… Mike O mally me an offer! Lol appreciate the fact that you have the talent to remake a masterpiece!!!
Looks cool. Email and let me know price. Thanks
Hey there. I’ve been following this thread since last August. I was curious if you are taking orders on the new pieces yet ? I would like a pair of them. Keep up the good work Danny boy…
Hey Arlynn,
Thanks for the support! I am adding the piece to the store this weekend. I will email the contacts who have requested this over the last year with a reminder and a link.
Hi Dan,
I have seen your pieces on Etsy and your website. I am definitely going to buy the 6″ model and was just wondering if you would make a package of the 6″ trophy with the keychain because I would really like to purchase both!! Please let me know if you would consider this!!!
Hey Erin,
Thanks for the interest and request! I will definitely take a look at adding a package deal to the store. I will email you when it’s up.
Best regards,
Dan
Let me know how quick I can get 10,000 units. Thanks!
– M. O’Malley
Are these replicas still for sale anywhere? I am very interested in purchasing one!
Hey Nick,
Thanks for the inquiry! I’ve been on a year break from Crags, however you have impeccable timing because I just sold a keychain last week and realized how much I missed making these things! I have the parts for a 6″ piece and I’m ready to sell those again too. I’m charging $50 for knick-knack and keychain(1.75″) sizes and $175 for the 6″ piece. Each piece comes with a CoA that is numbered and signed. If the pricing works let me know and I can set up a listing on etsy.
Thanks,
Dan