The first pour has hit a trouble. The form got a bit distorted, presumably from the heat of epoxy curing. So, to prevent more distortion, I'm doing the following steps:
1. I'll pour in layers. Each layer produces less pressure, so will distort less. Also, the amount of heat generated by a layer will be easier to dissipate.
2. I'll mix in a lot more sand. It makes the mix harder to pour, to the point where it barely flows if at all, but the amount of heat is again, smaller.
3. I'll add a lot more structure into the forms, so that even if the plastic becomes soft, it will hold shape better.
4. I've added a step at the edges of the leg bases, so even if there is some deformation, it will be hidden away.
To pour in layers, I printed all the parts, so that one batch fills about 3cm of depth. Here are the results of the first batch:
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