DSP Manual — Section 2 of 4
DSP Manual — Pages 4–6
Page 4 of 11
Model Armature & Clay Heating
Explanation of the custom foam armature design and clay heating methods. Safety warnings included.
The Custom Model Armature
The DESIGNSTUDIOPRO armature is a custom-designed solid foam structure. Unlike hollow armatures, the solid construction prevents cracks from forming in the clay during the modeling process. It also provides a clear visual reference for proportion — you can see the overall size and stance of the vehicle before any clay is applied.
Heating the Clay
Professional styling clay must be heated before it can be applied. The target temperature range is 130–150°F (54–65°C). Three heating methods are supported:
Toaster Oven
Place clay blocks on a foil-lined tray. Set to lowest temperature setting. Check every few minutes.
Igloo Cooler or Styrofoam Cooler
Use a 40 watt lightbulb to warm the clay. Line the cooler with aluminum foil first. Drill a 1" hole in the side of the cooler. Buy a lightbulb female socket and attach it to an extension cord. Only the lightbulb should be exposed to the interior space of the cooler. Be very careful not to overheat the space. If the temperature is above 155 degrees, lower the wattage of the lightbulb.
Commercial Clay Oven
Professional clay ovens maintain precise temperature. Ideal for extended modeling sessions.
⚠️ Safety Warnings
- Do NOT overheat clay above 155°F
- Do NOT microwave the clay — uneven heating will damage the material.
- Children under 18 must be supervised by an adult at all times.
- Handle heated clay with care — it retains heat and can cause burns.
- Keep clay away from food surfaces and wash hands after handling.
Page 5 of 11
Clay Properties, Tools & Steps 1–2
Clay safety and storage, tool descriptions, sharpening instructions, and base plate grid setup.
Clay Properties & Storage
DESIGNSTUDIOPRO styling clay is wax-based, non-toxic, stable, and fully recyclable. It can be reheated and reused multiple times. Store unused clay in the DSP box to maintain optimal temperature and prevent contamination.
Clay Modeling Tools
Rake
Used for rough shaping and removing large amounts of clay quickly. The serrated edge creates grooves that are then smoothed with other tools.
Clay Plane
A flat blade used for smoothing and flattening large surface areas. Essential for establishing clean, flat planes on the model.
Slicks
Smooth metal or plastic tools used for final surface refinement. Available in various profiles for different surface areas.
Step 1: Sharpening Your Tools
Before beginning, sharpen all clay tools using 150-grit sandpaper. Run the tool edge along the sandpaper in a consistent direction until a clean, sharp edge is achieved. Sharp tools produce cleaner cuts and smoother surfaces.
Step 2: Marking the Base Plate
Using the engineering drawings as reference, mark a grid on the surface plate. This grid serves as your primary reference for proportion and symmetry throughout the entire modeling process. Place the wheel plugs at the correct wheelbase position based on the drawings.
Page 6 of 11
Templates, DSP Box & Steps 3–6
Making foam core templates, DSP box storage, skim coating the armature, dragging in surfaces, and establishing wheel openings.
Step 3: Making Templates
Templates are cross-section profiles cut from foam core board using the engineering drawings as a guide. They are used throughout the modeling process to check the accuracy of the clay form against the intended design. Make templates for the front, rear, and at least two body cross-sections.
DSP Box Storage
The DSP box is a temperature-controlled storage container. Between modeling sessions, place your clay model and unused clay inside the DSP box to maintain optimal clay temperature and protect the model from dust and damage.
Step 4: Skim Coat the Armature
Apply a thin skim coat of heated clay over the entire armature surface. This initial layer bonds to the foam and creates a base for subsequent clay application. Work quickly while the clay is warm and pliable.
Step 5: Drag In Surfaces
Using the rake, drag clay across the surface to establish the primary surface planes. Work from the centerline outward, using the templates to check your progress. The goal at this stage is to establish the overall form — not to refine details.
Step 6: Wheel Openings (Introduction)
Begin establishing the wheel opening positions using the wheel plugs as reference. Mark the wheel arch profiles on the clay surface. The wheel openings are critical proportion references — getting them right early ensures the rest of the model develops correctly.