Guide Polycarbonate Reservoir casting (A Cheapskate tribute...)

All right, I'm gonna do a worklog on how I cast polycarb, and if you're bold enough to try it, you can have fun like I do.

I'm using an experimental process for this run, so we're all gonna learn. I know there are very precise, repeatable methods (I normally use them, and will describe those in detail as well) but I've got a wicked idea, and I want to see if it will work...

First things first, we have to assemble our supplies. For most work, I use Castin' Craft resin and hardener. These are two separate items, not sold together normally. At this point, I need to go ahead and put the warning in.

THIS IS NOT TOY MATERIAL. THIS CAN AND WILL CAUSE SERIOUS BURNS AND PERMANENT LUNG DAMAGE IF ABUSED OR USED IMPROPERLY. MEKP is a seriously dangerous substance, more so than the wikipedia page suggests. This is because it is not water soluble, and will continue to burn you even under running water. Soap will neutralize it, but it will not reverse damage. Breathing the fumes for extended periods can leave you coughing up blood. Work outside if at all possible. If not, VENT WELL. I won't be held responsible for not paying attention.

I use the entire line of Castin' Craft dyes, developer and such. I've found nothing but good results, and other products do not produce reliable results. One of my neatest creations cannot be duplicated, simply because I dunno what I added to it.

I'll leave this post with some links to the materials that we'll be pouring while I set up the shots I need to demonstrate the process.

http://www.dickblick.com/zz335/20/
http://www.michaels.com/art/online/displayProductPage?productNum=gc0510
http://www.allcraftsupplies.com/c-7240/casting-resin.html

That'll get you started while I get out the toys.

 

The wax blank, and the mold used to create it. Normally these molds are used by themselves or with inserts to make the castings, but this time I'm trying something more unique with it. This will be more akin to lost wax casting process.



Removing the parting line as well as the extra flash from around the top lip of the mold. Clay carving tools are used to do this step. The wax has been in the refrigerator for 24 hours at this point.



The waiting blank, cleaned up and with a s939 RBX for a size comparison. This is my first real attempt at a thinner-walled casting. Most of my former work has been heavywall, kinda dumbfire stuff. This is new territory.

The blank should have perfectly smooth walls, and a carved, almost microcrystalline interior, while retaining clarity. What will I use to get this effect?

Why, jewelry casting investment, of course...

 

Right now the blank is curing in investment (nothing to see here folks, you ever played with plaster of paris?) and within an hour or so will be ready for unmolding. At that point, then the real fun begins.

The blowtorch part.

 

I can't wait to see the finished product

 

I've been looking at the same resin in hopes of making some clear lenses for my car. Sure I could buy some pre made... but that's no fun. Waiting for more on this one.

 

Thank You for your cooperation, Sir. If I could make this blink...

I propose they add this to the guides sticky.
10 million crazy questions will follow. I particularly like how you put my name in the title so I could find it.


I was wanting to make some taillight lenses too. I'm worried about how well they would hold up in the sunlight.

 

Working on the next part to this guide, I got my mold stuck. Fsck it.

Cheapskate, I love your work. If I could just design a case and send it to you to be made, I would. Since you enjoy my reservoirs so much, I figured I'd give ya the recipe.

 

What's all this about lenses? I guess I'm just going to have to watch... Because so far we have wax... which ... is opaque? ( I've never heard of this before ) <-Polycarbonate Casting

 

more more!

 

Guys,
Cheaps wrote "I was wanting to make some taillight lenses too. I'm worried about how well they would hold up in the sunlight."

Do they not make UV resistant poly avail to the public? Custom lenses would be sweet.

John

 

Moving on, the investment has set up, now to burn out the wax...







Rome wasn't built in a day, and this won't go fast either...





More after work...

 

Do you have to get all of the wax out, or is a coating inside the mould beneficial for releasing the final casting?

 

Seeing as I'm going to dunk the mold in a water bath after smacking it with a hammer, either works. If you do leave wax to "ease release", you'll have to boil it afterwards to get the wax off.

 

Cool. I'm thinking the smacking with a hammer part might vary from person to person. If I smack something with a hammer, it is usually obliterated.
I'm glad you like my stuff. I've already started stockpiles of pewter, brass, and copper, and I've always wanted to get into casting. So you know I always keep a close eye on your threads.
You mentioned something about being a Casting Craft developer. Why have they never made UV dyes? (HINT)

 

And progress...

Pics are self- explanatory. Will post finished res in the morning.

 

Is it morning yet?

 

Lost the whole casting. The bottom leaked, and I have a pretty, glossy landing and no mold.

Will do ya a special one in a few minutes. No custom mold per se, but I think I have the ideas down...

 

Now that has to really bum a person out! I was watching this, it's cool. Now it's on the landing? How you gonna get that off?
John

 

So it became a permanent Gatorade spill? Tough break!

 

Hey, what happened to this guide? It's gotta get finished Kayin! I really want to see some of this casting stuff.
I got thrown off by the investment term, so had to pull up google. I found this, that talks about making jewelry using the lost wax method, so I'm thinking investment is kinda like the outside form here that you'll pour the resin into. So you wrapped investment around your wax mold somehow (I'm slow, I could use the pics)

So I'm still confused... if its to be a reservoir, how do you get the interior space, rather than a solid block?
I'll start searching for some of your previous work, since it sounds like you've done this before, and see if I can understand more.

Are you planning on completing this guide? (I know you're busy building your cooling setup)