Here's how I've reproduced canopy's that I could afford to take a small chance with. The process is usually fool proof and it's quick.

* Find a shallow pan that is larger than the canopy that will hold water

* Glue the canopy to a plate similar to the one I used with a large hole in the center. The plate should be long enough to rest on top of the pan securely.

* Fill the pan with water to nearly the top, leaving enough room for the the water the canopy will displace.

* Lay the canopy / plate over the pan inverted

* Fill the canopy with the casting material of choice (such as Hydrocal plaster)

* Top the water off as you fill the canopy, leaving it a fraction of an inch below the top of the pan

For a large canopy it is best to add water and casting material in steps to avoid stress on the canopy. This method not only virtually eliminates stress on the canopy from filling it with the casting material, it also acts as a heat sink during the cure.

It's a good idea to cast a couple of removable handles into the canopy mold to assist pulling it out of the canopy. I'll do that on the Blue Angel canopy which I'll picture in the next post.

This produces a ready to use vacuum plug and it eliminates the foam and silicone step I used for the Blue Angel canopy.

BTW this is not a new process - I found the idea a while back, thought it sounded reasonable, then found that it really works!