Waterproof vacuum forms

Hi, this is my first time posting here so be gentle!

I am making vacuum formed styrene shells for casting concrete kettlebells.

The shells are 0.03 thick.

I put the two shells into boxes and then bolt them together.

Then i pour concrete into the mold.

Here’s the problem:

It leaks. When the some of the concrete leaks out, it ruins the surface finish.

Here’s what I’ve tried:

  • glued rubber (innertube rubber) to the faces
  • worked ok, but it was not durable enough
  • silicone caulking - would not adhere to the styrene

Any ideas?

Have you followed this video? Prop: Shop - How to Make a Vacuum Forming Machine - YouTube

Yeah, it’s a pretty good video.

Unfortunately, the video ends before the part that I need help with!

Kettlebell