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Thread: Casting some Aluminium Honeycomb
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4th April 2017, 07:46 PM #1
Casting some Aluminium Honeycomb
I scored some 6mm aluminium honeycomb panels 300x300x25mm a while back. Yesterday I cut two of the sheets in half, made molds to suit from corflute polypropylene sheeting, then cast them in Bright Blue Pearlex/Reflex Violet Pearlex/Translucent Scarlet Red dye and Bright Red pigment mix/Black pigment and a little Red pigment mix. I've cut them into large blocks (~45x25x150) blocks and will wait a while before I sand them to size (this is because epoxy can move in time as it fully cures). The blocks can then be used whole, or cut in half for knife scales, or cut in half the other way for large pen blanks.
Here are the offcuts, the larger ones I can use as pen blanks, sanded and a quick coat of clear lacquer to give you an idea of what they will look like.
offcuts.jpgNeil____________________________________________Every day presents an opportunity to learn something new
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4th April 2017 07:46 PM # ADSGoogle Adsense Advertisement
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4th April 2017, 07:53 PM #2SENIOR MEMBER
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Always pushing the boundaries and pioneering ideas..... Love your work Neil, and as always, very professional looking final products!
"All the gear and no idea"
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4th April 2017, 10:00 PM #3
Thanks mate. Aluminium honeycomb panels have been cast for a while now on the US forums etc, just I have been unable to get any till now in the smaller quantities. My last resort was getting my son in Seattle to send some from Amazon, but with the Chinese connection it worked out heaps cheaper anyway.
Neil____________________________________________Every day presents an opportunity to learn something new
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5th April 2017, 03:03 AM #4GOLD MEMBER
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Nice going Neil. I'm curious if you mix the resin and pour it over the honeycomb in the mould or do you pour the resin into the mould first and then lower the honeycomb into the resin? Would it make a difference to keep bubbles/voids forming?
Pete
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6th April 2017, 07:07 PM #5Neil____________________________________________Every day presents an opportunity to learn something new
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6th April 2017, 08:16 PM #6
Sort of looks like snake skin to me. I'm having trouble visualizing what a turned section will look like.
Franklin
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11th April 2017, 07:20 PM #7
Been casting a few panels and decided to make a couple of cutting board molds rather than using the sacrificial corflute panel molds. Cast another panel in neon pink and neon green. Each half panel took 1.2 litres, and yes they are bright
new mold ready to pour.jpg neon resin .jpg new neon casts.jpgNeil____________________________________________Every day presents an opportunity to learn something new
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19th April 2017, 11:04 AM #8Skwair2rownd
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I have saved some fairly heavy duty honeycombed cardboard for the same use and have given thought to
using coreflute for the same purpose.
Be interesting to se your finished pens.
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19th April 2017, 11:42 AM #9
One thing with the core flute is be careful with large pours. I've found it is fine for the smaller molds but the big ones it tend to bend/deform from the weight/heat of the cast. I ended up making some more cutting board molds for these honeycomb casts. I find the epoxy shrinks a bit and the whole cast comes out by knocking the mold on the ground
Neil____________________________________________Every day presents an opportunity to learn something new
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23rd June 2017, 07:22 PM #10
Well I ended up casting 6 slabs, each a different colour, giving 6 knife scale/pen blank blocks ~45x25x150 from each
Black with some Red, Blue, Neon Green
black with red block.jpg blue block.jpg neon green block.jpg
Purple, Red with some Black, Neon reddy Pink
purple block.jpg red with black block.jpg reddy pink block.jpgNeil____________________________________________Every day presents an opportunity to learn something new
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13th August 2017, 06:41 PM #11
I bought a Kershaw Chill, a small flip knife, but didn't like the black G10 scales and decided to make new ones from one of my scale blocks. I used some 0.6mm aluminium sheet glued to the back of a 5mm slice to give them strength, but also to enable me to counter-bore the C-Tek and use the existing tiny bolts. It is only a small knife, 9.8cm long closed/17.8cm open, so good for a female especially in the bright pink scales. It only took one 5mm slice to make both scales. Finished with Rustins Plastic Finish
Closed
closed 1.jpg closed 2.jpg side on 1.jpg
Open
open 1.jpg open 2.jpg side on 2.jpg
finished scales and with old G10 ones
new scales.jpg old and new scales.jpgNeil____________________________________________Every day presents an opportunity to learn something new
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