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  1. #1
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    Default Casting aluminium - a simple way

    I've done a bit of home casting with aluminium over the years to make gear blanks and done a bit of experimenting with small pendants etc and it's always been OK, but could be better.

    To do it properly you need the special sand, and a muller, and there's a whole lot of friggin around involved.

    Anyway saw this video on you tube which I recon is pretty interesting and seems to get good results with just foam, plain sand and some plaster.

    So I'm going to give it a go when I get a few jobs out of the way.

    Iron Cross: Lost Foam Casting Cast in Aluminum - YouTube

    Anyone been down this particular path ?

    Cheers

    Rob

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  3. #2
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  4. #3
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    Default Have a look at my balls

    Yep I have had a few goes at this method with pretty good results. It’s good for one off jobs where making a timber pattern would be a waste of time.
    One thing though unless you need a really fine finish you don't need to use the “drywall mud” as long as you use nice fine sand that is clean (unlike what the bloke in the video used).
    I bought “play sand” from Bunnings and that gave the castings a pretty good finish for what I needed as it is a nice fine sand.
    I was casting a few round handles for my lathe and used styrene balls available from art shops. As I was going to paint the final product it didn't matter if the as cast finish was a bit rough. As it turned out the finish wasn't too bad .
    Sorry I forgot to take a pic of the unpainted balls. I would like to get hold of some of that pink or blue foam but so far havent been able to fined any other than a 1200 x 2400 sheet which would be a lifetime supply.
    The white polystyrene foam works well but its a little bit more coarse than the pink stuff.
    If you get into this method of casting you will need to make yourself a hot wire foam cutter which opens up an entire new world of possibilities with this stuff.

    Bill
    Lathe knobs.jpgpolystyrene balls.jpg

  5. #4
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    I posted pictures of a sophisticated hot wire cutter some time ago
    https://www.woodworkforums.com/f65/so...stings-151420/
    I still have wire if members want some (PM me, I'll send you my address and if you send me a SAE I'll send back a few metres)

    Michael

  6. #5
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    Default

    Great looking balls you've got there Bill.

    I'm itching to try out this method, but the biggest problems are the weather (wet) and I can't think of anything I currently need to cast.

    I have previously used sand and ATF mix as the casting medium, and it's reasonably OK, but very fragile when used with conventional casting techniques.

    This foam bizzo looks good, and I can see myself maybe doing intricate mould cores by shaping the foam with my little pencil die grinder.

    Will play around with it to see how much mess it makes. That foam is electrostatic sticky mess to clean up usually.

    Interesting topic.

    Cheers

    Rob

  7. #6
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    Ueee is offline Blacksmith, Cabinetmaker, Machinist, Messmaker
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    Hi Rob,
    You asked in the video comments about Plaster of Paris, i commented there but i thought i'd throw it in here as well. I'm pretty certain POP will only withstand temps up to about 200degC, after that the water that is trapped in the hardened plaster breaks free and the plaster just turns back to powder. Thats how i remember it happening anyway.....could be wrong. Not sure how GB is any different though?

    Cheers,
    Ew
    1915 17"x50" LeBlond heavy duty Lathe, 24" Queen city shaper, 1970's G Vernier FV.3.TO Universal Mill, 1958 Blohm HFS 6 surface grinder, 1942 Rivett 715 Lathe, 14"x40" Antrac Lathe, Startrite H225 Bandsaw, 1949 Hercus Camelback Drill press, 1947 Holbrook C10 Lathe.

  8. #7
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    Default

    Thanks Ewan. I will give it a go.

    The main worry was how it would go flash steaming.

    Apparently provided you keep the coating thin and dry it well it should be much the same as dry wall plaster.

    Anyway, it looks like a great way to do casting, so I will definitely give it a go when things dry out a bit.

    My furnace is outside (bricks, wood, and a vacuum cleaner blower) -

    Rob

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