You might want to have a look at the Little and Lewis website (Littleandlewis.com) In my opinion, they are the premier sculptors in this art form, creating HUGE and sturdy gunnera and other giant leaves with beautiful coloration. They hold their process as a closely guarded secret, but the website is certainly an inspiration. As far as step-by-step goes, I recall there being an article in either Sunset or BH&G magazine maybe a year or more ago that featured a "how-to" section. Good luck and post YOUR pictures!

Zenzone

Do a google search for hypertufa leaves or just hypertufa

I have been making cast leaves for a few years and am more than happy to show you some of the ones I have made. Granted I am not Little and Lewis and haven't made huge ones yet, but here are some pictures. Check out the hypertufa forum for more information.

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absolutely beautiful and such sharp edges great job