Part I: Making a Plaster Cast of your Ear

Step 1: Put swim cap on and put Vaseline on hair near ears. Mix 1 cup room temp. water with 1/3 Mold-Gel with electric beaters on low. Stir with hand to get air and remaining lumps out.

Step 2: Put bottomless margarine tub over plugged ear with Vaseline coated around edge of tub.

Step 3: Pour Mold-Gel mixture into tub, making sure tub is firmly against head. Leakage is likely so be careful. Hold cup on until Mold-Gel is firm (about 5.5 minutes from when it touches water; sets faster the warmer the water is)

Step 4: Gently pry mold off of ear. The mold will be soft so pull carefully.  Repeat steps 1-4 on other ear. Let molds dry for a few hours.

Part II: Creating the "Positive" of your Ear

Step 5: Take the molds out of the tubs and put them in different tubs with the bottoms still intact. You may need to put a ball of clay in the bottom of the cup to keep the molds from sagging and therefore distorting. Make a wall around the edge out of clay about an inch high.

Step 6: Pour several inches of water into a mixing container for the plaster mix. Spread plaster on surface of water with your hand. When the plaster forms an island on top of the water and has a difficult time sinking in, shake the container so all the plaster is submerged. Wait 5 minutes to let the air dissipate. With hands, mix by squeezing out the lumps till it's smooth. Should have consistency of thin yogurt.

Step 7: Pour plaster into molds. Thump on table to get any and all air pockets and bubbles out. Let sit for at least 2 hours.

Step 8: Separate Mold-Gel mold from plaster mold once plaster is completely set. Using a craft knife, file off any lumps or imperfections and the shapes made from the ear plugs.

Part III: Shaping the "New" Ear

Step 9: Using modeling clay on molds, shape out what you want your ears to look like. Make the edges very thin. Fill in any undercuts with clay (including behind the ear), and cover the rest of the mold with a layer of clay, leaving a space between the clay of the part that would be the prosthetic. Build another wall around the mold that's higher than the ear (1 inch should be enough). 

Step 10:  Spray mold with silicon spray or cooking spray or coat in Vaseline. 

Step11: Pour another plaster mix into the mold (repeating step 6)

Step 12: Gently separate the two molds. Remove clay from the positive that represents the prosthetic. Fill the undercuts in with clay again. Carefully make a space behind the ear by removing the clay from that area so that when the gelatin is poured in, the prosthetic will have a backside to it.

Part IV: Casting the Ear

Step 13:  Coat positive and negative molds with a thin layer of Vaseline. Melt foamed gelatin in a container in the microwave (don't let it boil). Pour the melted gelatin into the negative, making sure it fills all spaces. Put positive into negative (gelatin will be displaced and squeezed out) and weight it (several large books, or even standing on it for a few minutes).

(not drawn to scale)

Step 14: VERY carefully separate molds, and pull out gelatin. Trim off excess. Should look like the prosthetic and fir nicely on your ear. Color with makeup (cream foundations, blush, eye shadow). Attach with spirit gum or Pros-Aid.

By repeating step 13 you can make as many as you want. Always be gentle because the molds can break.

Here are the final results!