Special Travel Mugs WIP

**dai sensei** · 26th October 2012, 08:30 PM

Ok been casting everything under the sun, and as I need to new mug in my new camper thingy, I decided to cast up some traveller mug blanks. I started with a croc blank, then realised someone is sure to ask for WIP photos, so started another one with the last of the Liquid Amber Seed pods Wood Hacker gave me (thanks mate).

I start by turning some timber molds, one for the outside that is a hollow tube of sorts but with tapered inside, the inside one a flat bottomed conical shape. The inside needs to be ~1-2mm less than the actual cup, the outside hollowed out to leave ~20mm gap. I just used some green umbrella tree branches from a tree I cut down a few weeks ago (intending to use the wood for spinning tops).

mug mold1.jpg mug mold2.jpg

I then started gluing on the pods to the inside mold with super glue, after sanding a small flat bit on the bottom. I try and aim for the final outside of the mug to be the centre of the seed pod (ie when the wall is ~10mm) but I didn't get it right

. After leaving to dry, I then sanded them down to form an even thickness approximately the same as the gap. By trial an error, you keep sanding until it is a snug fit, with the top of the cone mold (the tennon), even with the top of the outside mold.

mug seed pods1.jpg mug seed pod2.jpg mug seed pod3.jpg mug seed pod4.jpg

To cast I half fill the outside mold with resin, then place the centre part in twisting as I go, until it jams in tight with the top of the tennon in line with the top of the outside mould. I then place it all in the pressure pot and top up the resin to the top of the mold. With the pressure and shrinkage the set resin lines up with the bottom of the tennon, perfect for turning it later.

cast mug.jpg

The we use the exposed tennon at the top in the chuck and turn off the outside mold. The resin doesn't actually stick to the green timber, so I next turn a new tennon on the base of the cast, to be used for hollowing out the inside mold in the next step.

rough turn mug.jpg

The final photo shows both blanks, the mug liner, I'll post more pics after I stabilise them as is.

rough turned mugs.jpg

Cheers

**Perfect Pens** · 26th October 2012, 11:15 PM

As usual nice work Neil, Looking forward to seeing the finished item

Cheers
Tony.

**SDB777** · 26th October 2012, 11:27 PM

Was wondering....

Did the resin act any differently with the wood being 'green'(think you stated that it had been recently cut)?
Did you need to put the pods into a oven or anything prior to putting them on the 'mold'?

Final question, I promise(fingers crossed behind my back)....how long did you pressure, and at what PSI?

Scott (saving to favs for the outcome) B

**wood hacker** · 27th October 2012, 12:40 PM

Originally Posted by dai sensei

Liquid Amber Seed pods Wood Hacker gave me (thanks mate).

No worries Neil, glad they have been put to good use. Have you turned up any of the ones you cast as pen blanks?

The croc jaw coffe mug will certainly be an eye turner i reckon.

cheers
WH

**dai sensei** · 27th October 2012, 09:14 PM

Originally Posted by SDB777

Was wondering....

Did the resin act any differently with the wood being 'green'(think you stated that it had been recently cut)? I sealed it first with a thick layer of Nitrocellulose Sealer, otherwise yes the green timber does react, leaves a gooey mess.

Did you need to put the pods into a oven or anything prior to putting them on the 'mold'? Yes, a dehydrator, but they were pretty dry to start with

Final question, I promise(fingers crossed behind my back)....how long did you pressure, and at what PSI? Overnight at 45psi

Scott (saving to favs for the outcome) B

Originally Posted by wood hacker

No worries Neil, glad they have been put to good use. Have you turned up any of the ones you cast as pen blanks?

The croc jaw coffe mug will certainly be an eye turner i reckon.

cheers
WH

Too busy casting and cutting up timber (see timber milling sub-forum) to turn pens

**plantagenon** · 4th November 2012, 08:28 PM

Well, where's the finished product?

**dai sensei** · 4th November 2012, 10:01 PM

Too busy with carports, slabbing timbers and entertaining more interstate visitors with stabilising croc jaw and corn cob pen blanks

. I wanted to stabilise them this weekend but it didn't happen. Next weekend some Red cedar is waiting for me, so could be a few weekends away yet

.

**plantagenon** · 6th November 2012, 10:09 PM

I know what it is like. I have been retired for over 2 months and I have got to the shed once. The more time you think you have - the less you actually have. Ohh, for work and my own time again.

**Dorno** · 11th November 2012, 07:04 PM

I will take part of the blame

because I am one of those interstate visitors LOL but I must say it was well worth calling in to see Neil but more on that when I get home on wednesday.

Cheers Ian

**dai sensei** · 11th November 2012, 10:35 PM

Days slabbing, casting/stabilizing crocs, relies asking for odds and ends to be made, planning for carports, plus picking up burls/branch caps from miles away like today all add to delays

Plus I don't cast/stabilize when it's raining

**bosox** · 13th November 2012, 07:09 AM

Please keep us posted for the progress of your project.

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