The first step in making a duck decoy out of foam is to purchase an aluminum, duck-shaped mold from your local sporting good store. If you can't find it there, then perform a search on the Internet in order to find some suppliers. Most molds are made so that the head and the body of the decoy are formed separately, then assembled later. The best molds can be used with a tool that is purchased separately. This tool, called a "mold extractor" allows you to turn it into the mold so that the formed pieces are pushed out. You will also need some two-part urethane foam, as this material makes the best decoys. This urethane foam is much safer to use, and, it comes in different colors.

The second step is to wipe out the inside of the molds. Then, lightly coat the inside of the molds with a good quality liquid car wax. This will help the decoy come out of the mold easier. Make sure that you get the wax inside all of the cracks and the crevices. A cotton swab might be helpful in this step as long as you don't leave blobs of wax in the mold. Then, allow the liquid car wax to dry for a few minutes.

The third step is to put on protective eyewear as well as some waterproof gloves. Then, follow the manufacturer's directions on the urethane foam container in order to achieve the best results. Basically, though, you will measure out equal portions of both parts of the foam. Use an old plastic container for this purpose. Then, mix the two parts together thoroughly. Immediately pour the foam into the molds and place the top halves on. Use several "C" clamps to hold the halves of the molds together. Mix up more of the urethane foam, if needed, to fill all of the molds.

The fourth step is to wait the required amount of time (according to the manufacturer's directions), then remove the clamp from the molds. Use the mold extractor or a large - bladed screw driver to remove the parts of the decoy from the molds.
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Karl Fisher Titration