Hello, Gordon Stelter and MMD -- Just a week or so back, I bought two
chemicals from Smooth On Company, in order to make new Pianola "P"
pedal mats.  Instead of paying $10,000 to have a mold made, I will
make a mold from an original pedal.  Then, with the second chemical
which sets to a tough black rubber, I will make new pedal mats.
It's so easy to do, an amateur can do it perfectly the first time.

Basically, here is what I would do: If the original mats are truly
flat, I would spray release agent on one, and lay it face up on a piece
of glass.  Then I would construct a wooden frame around it.  Since the
mats probably measure about 10" by 5", the wood frame should be about
11.5" by 6.5" on the insides; this way, you have a 3/4" space between
the edge of the mat and the inside of the wood frame.

I would use modeling clay to hold the wood frame to the glass.  All
you have to do is roll the clay so that it is a cylinder about 1/2"
diameter, and then push it onto the outside perimeter of the wood
frame.  This will keep the four pieces of wood together, and also
prevent any liquid from leaking out.  Then you pour the mold making
chemical into the frame and wait a few hours until it is a block of
rubber.

When you take everything apart, you will have a block of rubber with
a negative impression of a pedal mat.  Simply spray a little release
agent into the cavity, and pour in the casting material.  You will have
a perfect copy of the original, so after making a second mat you will
be finished.  The cost should be around $50.00, which is a lot better
than $10,000.00.

I believe I have enough chemicals to make two different molds, so if
you mail me one of your mats, I could make a mold for you.  I'm sure
the mats are rock hard at this point, so put it in between two pieces
of wood if you want to mail it unbroken.

You can find Smooth On with Google.  The chemicals I bought to make
the mold is "Oomoo 25" Liquid Rubber Compound.  The chemical to cast
the pedal mats is "Task 13" Black, semi-rigid rubber compound.

Randolph Herr