Very cool and thank you for the info. I have a project that I have been working on in 1/4" aluminum. Due to the intricacies of the design, it is proving to be a daunting task. This cold casting process is looking like it might just be the ticket. I plan to now carve my design in a hardwood and use that to create two plaster molds which I could then cold cast into.
Where in Florida are you? Perhaps I could then send my finished parts to your friend for chroming?
btw, the pieces would not be either strutural or near any heat sources.....