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HT1
12-29-2010, 05:21 PM
I followed the instructions in this post
http://www.backyardmetalcasting.com/forums/viewtopic.php?t=1806&highlight=letters

you can see my results.

http://i56.tinypic.com/2lsk5ep.jpg

not having, and not really willing to buy pewter, and not in the mood to handle lead that regularly, I'm pondering casting bondo pattern letters. of course I assume bondo would stick in the mold, what would make a good parting between aluminum, and bondo?

P.S. I have done this twice, with 1/2 inch, and 3/4 inch letters, the only letter that gave me any problem was the center of the A

_3D_
12-29-2010, 11:30 PM
Vaseline or spray silicone, I say.

(Sigh) I definitely have to make a thread on how I do lettering. Maybe next year?! :)

_3D_

Metalshopteacher
12-30-2010, 03:17 AM
I don't know how bondo would work, but what about a thick heavy wax of some type?

DarkArtiste
12-30-2010, 04:27 AM
everyone always goes for the petroleum jelly or silicone for non-stick barrier coats.

Don't forget to consider the possibility of dry graphite sprays like Jig a Loo.

I prefer them to vaseline and silicone for many many reasons. The graphite is basically inert, I've never had it react with anything or turn my mold rubber into sticky goo. If it migrates along from process to process it won't contaminate anything in the finish stages such as paint like silicone products can. It's dry and doesn't telegraph anything such as fingerprints, and it doesn't act like a piece of flypaper like vaseline can.

mite5255
12-30-2010, 04:41 AM
I followed the instructions in this post
http://www.backyardmetalcasting.com/forums/viewtopic.php?t=1806&highlight=letters

you can see my results.

http://i56.tinypic.com/2lsk5ep.jpg

not having, and not really willing to buy pewter, and not in the mood to handle lead that regularly, I'm pondering casting bondo pattern letters. of course I assume bondo would stick in the mold, what would make a good parting between aluminum, and bondo?

P.S. I have done this twice, with 1/2 inch, and 3/4 inch letters, the only letter that gave me any problem was the center of the A
If using bondo and if its the same as body filler we use here in Australia you can mix styrene monomer with the bondo so you can thin it so if flows more readily

Mike

Metalshopteacher
12-30-2010, 06:42 AM
everyone always goes for the petroleum jelly or silicone for non-stick barrier coats.

Don't forget to consider the possibility of dry graphite sprays like Jig a Loo.

I prefer them to vaseline and silicone for many many reasons. The graphite is basically inert, I've never had it react with anything or turn my mold rubber into sticky goo. If it migrates along from process to process it won't contaminate anything in the finish stages such as paint like silicone products can. It's dry and doesn't telegraph anything such as fingerprints, and it doesn't act like a piece of flypaper like vaseline can.

I don't know if you would consider it in the same category but in my fishing weight molds (aluminum molds for lead) I take them over to the welding booth and use a straight acetylene flame and blacken them with the soot. The casting just falls out of there. Not to mention it also helps preheat the mold for the lead :P

Metalshopteacher
12-30-2010, 06:46 AM
I actually though about doing something similar to this about 2 months ago, may daughter has this alphabet board, has all the letters of the 'bet on it, the letters cant be larger than 3/4" and they are made of foam. I was thinking of trying some lost foam casting with them but then I got my CNC mill going and haven't looked back. Perhaps that's an idea for someone to try. They came in a sheet with all the foam letters could be pushed out.

petersenj20
02-12-2011, 04:38 AM
Sorry for reviving an old post. Been a while since I was here.
I don't mean to be rude, but this isn't what the Shopnotes was discussing.

It was made in such a way that the two lines of letters were individually attached by a sprue/runner and were able to snap from the runner. How do you separate your letter from the large Runner?

Bob S
02-12-2011, 12:48 PM
I posted this method I had used a while back but here it is again.

I cast up this plaque with letter size I wanted and then milled off most of the back. If you go completely through you will break off letters at the edges of the cut. It's better to stop short of cutting through and by hand on a belt sand remove the remaining back to obtain the letters needed. It worked for my. I, however, have recast letters from my letter fonts so I had extras and did it simply as a regular casting with small gates leading to some part of the letters which allowed easy removal later. :wink: Bob

http://i122.photobucket.com/albums/o268/castaway43/DSCF2865.jpg

http://i122.photobucket.com/albums/o268/castaway43/DSCF2868.jpg

Jammer
02-12-2011, 11:59 PM
I just got some letters and number for a menu board from e-bay. They are 1" plastic letters. Look like they will work real nice.

Letters & numbers (http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=280560578150&ssPageName=STRK:MEWNX:IT)

I'm thinking of casting some in Zinc or a ZA27 to have metal letters but I don't know if that will be nessesary. They have small tabs on the back to press into the board, I can use them or trim them off and glue them to the pattern. I want to get a set of 3/4" and maybe some smaller ones.

Rocketman
02-13-2011, 08:09 AM
My local AC Moore craft store has wooden letters & symbols from 3/8 up to 2". They're all cut from hardwood & have proper draft on them, and their font is nice enough to make plaques with.

They're pricey but if you got one whole set & duplicated them it might be worthwhile.

HT1
02-17-2011, 02:13 AM
A quick update,

I made a silicone caulk mold, and have been making pattern letters with "thinned" Bondo(body filler) it works pretty good, save the letters are not reusable like the pewter pattern letters. but in a pinch when you need that one additionl letter for a projectk it is quicker then express mail

mite5255
02-18-2011, 06:05 AM
A quick update,

I made a silicone caulk mold, and have been making pattern letters with "thinned" Bondo(body filler) it works pretty good, save the letters are not reusable like the pewter pattern letters. but in a pinch when you need that one additionl letter for a projectk it is quicker then express mail

Hi HT1, did you use styrene monomer to thin the body filler

Mike

ragingslab
03-22-2011, 11:34 PM
I just bought some white, 3/4" and 1" letters from this Ebay seller (http://cgi.ebay.com/Vintage-New-Pepsi-White-1-Menu-Board-Letters-Numbers-/140496040559?pt=LH_DefaultDomain_0&hash=item20b637726f) . They arrived today. They are about 1/8" thick. Not much, if any, draft. We'll see if they of any use.

mite5255
03-23-2011, 12:00 AM
I just bought some white, 3/4" and 1" letters from this Ebay seller (http://cgi.ebay.com/Vintage-New-Pepsi-White-1-Menu-Board-Letters-Numbers-/140496040559?pt=LH_DefaultDomain_0&hash=item20b637726f) . They arrived today. They are about 1/8" thick. Not much, if any, draft. We'll see if they of any use.

I have been trying to find someone here in Australia that supplies those letters, so far no luck. If the work for you I'll contact that seller and see if he'll send some out here

Mike

Murray
03-23-2011, 12:50 AM
Do you have a "Staples" (an office supply store) in your area? They have those for dirt cheap, they have little tabs on the back I think but super cheap and do the job very well!

Murray

mite5255
03-23-2011, 01:54 AM
Do you have a "Staples" (an office supply store) in your area? They have those for dirt cheap, they have little tabs on the back I think but super cheap and do the job very well!

Murray

Yes Murray we do, we have a chain office supply store and I have tried them twice and there answer is no, I then tried a locally owned store and they gave the same answer. I'll give them another try

Mike

nudge
03-23-2011, 06:25 AM
mite5255

Have you tried "Spot light" ? just a thought.

mite5255
03-23-2011, 06:31 AM
mite5255

Have you tried "Spot light" ? just a thought.
Yes nudge I have. Went again to office supply store and they now have them BUT they want $60.00 a sheet like on E bay, so Iv email that person on E bay and have ordered 2 sets of each size. at the moment I'm waiting for the invoice

Mike

mite5255
03-23-2011, 06:34 AM
It may interest you to know nudge, a Kiwi Company, Fletcher Building has brought out the Company that I work for

Mike

Robert
04-30-2011, 07:28 PM
Ragingslab brought this up originally. I just bought these letters off ebay at his recommendation. They look great and are pretty cheap. About 1" high and 0.1" thick with about 5 deg of draft. Everyone needs a set!

http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=280560578150&ssPageName=STRK:MEWAX:IT

http://i.ebayimg.com/00/$(KGrHqJ,!l!E2EgPVKO5BNpI,sE,Mw~~_12.JPG

R

greencheapsk8
04-30-2011, 10:25 PM
$4!? Aw man, stupid american sites not being in NZ..... :evil:

w3
05-01-2011, 12:26 AM
Green, I would bet two or three of those sets (or more) would fit into a small flat rate box ($13.95). Have them mailed to a forum member then trans shipped to you after breaking them down, split with nudge and save half the shipping.

w3

donkey
05-02-2011, 08:45 PM
I was looking at some cake decoration letters on Ebay, same idea but smaller. 12mm high. Should have bought them.
Donk

mite5255
05-03-2011, 09:55 AM
Hi Green.If you want to try before you buy I have a few sets of 3/4, 1 inch and 1 1/2 of those letters, if you pm me you postal address plus what words you what to try and I'll post them over to you

Mike

mite5255
05-03-2011, 10:06 AM
I got my letters from this EBAY seller here. (http://cgi.ebay.com/Hard-find-BLUE-1-New-Pepsi-menu-board-letters-/130514570317?_trksid=p4340.m263&_trkparms=algo%3DSIC%26its%3DI%252BC%26itu%3DUCI%2 52BIA%252BUA%252BIEW%252BFICS%252BUFI%26otn%3D10%2 6pmod%3D140517852729%26ps%3D63%26clkid%3D888704015 8995430917)

Fixed long url that was breaking the page.

~Anon

evlwht-guy
05-04-2011, 01:06 AM
Hey, greencheapsk8 dont complain about ebay sellers being in the
us....move here...If you are a foundry hobbyist you probably are willing to work for your living....we need more actual stupid hard working tax payers to help pay off the $55,000 in national debit we have over her for every man woman and child......not to mention all our deadbeats!

Pleeeese move here we need you!!!

Bob S
05-07-2011, 05:29 PM
I needed smaller letters, like 1/2" and 3/4" so I paid the big buck for fonts of 1/2" and 3/4" of standard foundry letter fonts made in zinc metal. Problem was having enough letters to write a complete line of text or a large line using several of the same letters but not supplied in a standard letter fonts.

So I just cast the letters needed in aluminum to complete the sentence line required. Over time I have more then enough extra letters to do most lettering jobs required. Often time the letters just stay glued in the patterns for later use and just make more to replace them. :wink:

I take the letters and press them into a flat rammed up drag section and then place a wooden gate bar between the letters, powder and ram up the cope. I open the flask dump out the letters and cut the small jointing gates on the back side of the letters so when complete the letters can have the gates removed from the backside without affecting the front of the letters themselves. These letter only require a small amount of clean up on the backside to be ready for pattern use, easy peasy. 8) Bob

http://i122.photobucket.com/albums/o268/castaway43/015-2.jpg

http://i122.photobucket.com/albums/o268/castaway43/033-1.jpg

Flaming Furnace
05-09-2011, 04:42 PM
The letters you casted are looking absolutely great. I was looking before to buy some letters and I didn't find what I was looking for. I wanted to cast an aluminum plaque for my foundry site (new domain). Then I walked one day to our local supermarket and found foam sticky letter the exact size I needed. I didnt know if it wiould work with the sand moulding but it turned out better then I expected. :lol:

http://2.bp.blogspot.com/-5Po5gTQfIbU/TbsuDAoUu4I/AAAAAAAACFU/cdPw8xuY13c/s1600/flamingfurnace%2Bplaque%2Bnew%2B%2Bflask.JPG

http://3.bp.blogspot.com/-trCwpDedWbQ/Tbsyeklvi6I/AAAAAAAACFc/4Rv8-pMvwg8/s1600/pattern%2Band%2B%2Bsand%2Bimpression.JPG

http://2.bp.blogspot.com/-niMkUygnKFY/Tbs4_4TpSgI/AAAAAAAACGU/V0-3EHdPedM/s1600/flamingfurnace%2Bplaque.JPG

http://2.bp.blogspot.com/-jQJgtUolsdI/Tbs4_-TpUdI/AAAAAAAACGc/iib2DYxfFBA/s1600/flamingfurnace%2Bpolished%2Bplaqued.JPG

For more details of my casting cheak my site:

Flaming Furnace (http://www.flamingfurnace.com/)

jgro
05-10-2011, 03:20 AM
Nice website!

jgro