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First I had to make the sculptures, and build boxes around them to define the edges of the molds. The brickwork is a plastic sheet from the local hobbystore (I didn't feel like sculpting all the brickwork from scratch!), I raised the wall using sculpey, and build up support bastions also from sculpey but I faced them with strips of sheet styrene to ensure mostly flat surfaces :)

the boxes are made from foamboard, I used hotglue to seal the seams.

I even added an Imperial Eagle there over the doorway - it wasn't as hard to make as I thought it would be!

I also made a larger Imperial Eagle symbol to be used to define important Imperial buildings/locations

I sprayed the recommended release agent onto the sculpts & the box interiors before I poured the mold material in.

It took two gallons of the Por-A-Mold medium strength mold material to fill the two wall molds and the mold I build up around this Eagle sculpture. Luckily for me I'd purchased a 2 gallon kit (hey sometimes ya get lucky!) ;)

After pouring the polyeurethane into the molds and allowing a full 24 hours to cure the moment had come to remove the original sculptures - this took a lot longer than I'd thought it would (despite my using the recommended mold release agents).

but finally I was done, the molds came out great :)

it's sometimes hard to get all the clay out of molds like these but I've found that the first cast usually takes a lot of the remaining clay out with it - so I poured in some plaster to make the first casts...

here are the unpainted plaster casts shown with some Space Marines for scale - I know the walls may look a little crooked but let me assure you they are straight & even - it's just that they are large enough to show some perspective distortion here in the photos :)

the large Imperial Eagle came out well, despite having some clay stuck in some of the details I went ahead and poured the first cleaning cast

you'll notice the toes didn't all come out, I'm pleased to report the clay which botched this one came out when I pulled this piece - I don't know if the next eagle will be perfect - but I am confident it will have better definition than this one :)
 

I then went ahead and painted it, chaos black base, then painted the highlights boltgun metal & hit it with a black ink wash 

I think when combined with other 40K terrain this aquilla will be a great accent piece :) and very handy to have for the occassions when we need to model up a desecrated Imperial Shrine too, a fractured aquilla will be a very high drama terrain accent!

I hope you've enjoyed this little overview of the project, I will post pics of the buildings I make when I get them done!

fun games for all! ~ Brother Edward