On Friday, May 8, 2015 at 2:48:19 PM UTC-4, Per Carlin wrote:
Look for a local foundry that can cast lead. Make a piece of wood in the correct shape and they can make a set for half the original price from AS.

I use plaster to make molds, then melt lead fishing weights to make "weights". In this case, I would make a "wood blank" with the required dimensions (allowing a slight taper on the sides for a draft angle, lay the blank on a flat smooth surface (narrow side of the draft angle up)and pour plaster over the top of it & let harden. The draft angle eases removing the lead bit later & the mold should last for a number of casts.
In Kirk's place, he just needs the dimensions so he knows how big to make the mold (including depth).