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  1. Hand-Schaub's Avatar
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    Sep 26, 2002, 11:35 PM - Aluminum Helemt Casting Process -A real Hand-Schaub! #1

    A lot of people ask me how my Fett helmet was cast in Aluminum. Well, for starters I work at a comercial foundry so that helps But all the work you see in this thread was done primarily by me. I'm very proud of my newly sculpted and cast helmet at this thread:
    http://forum.thedentedhelmet.com/vie...c=2355&forum=2
    but I have pictures of The helmet I cast several months ago. (the Deluxe - which I only made one of)


    Each one is hand cast in wax from a mold (the new sculpted helmet was molded and cast the same as this one)

    - then cleaned and gated (this is where modifications for Jango or Boba come in).

    a silicate waste mold is formed over the gated wax

    then the wax is melted out (holes are drilled to relieve preasure on the shell)

    The holes are patched up and the shell is checked for leaks and painted with this stuff to make the shell stronger (we did a bit of an overkill on this one. It is placed in the kiln to reheat the now hollow shell


    Here is the furnace where the metal is melted. We are heating up aluminum cutoffs before putting it in the pot.

    This is me getting ready to pour the metal (it's about 120 degrees in the foundry)

    pulling the pot out of the furnace

    the shell is removed from the kiln and racked close to the furnace


    Here I am actually pouring the metal into the rangefinder

    a view inside the cup with the still liquid metal inside the shell

    after the metal solidifies, we can break the shell and start the clean up process (cutting off the gates and grinding away all the imperfections)


    The final result of the Deluxe casting:
  2. Admin Staff Star Wars Chick's Avatar
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    Sep 27, 2002, 12:16 AM - Re: Aluminum Helemt Casting Process - by TK-581! #2

    Wow, that is an amazing amount of work! Really awesome!!!
  3. Well Paid Killer's Avatar
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    Sep 27, 2002, 3:12 AM - Re: Aluminum Helemt Casting Process - by TK-581! #3

    Unreal man, what a rush to actually forge your own real armor!!!!!!!!! I've worked with pouring Bronze and its not the easiest to work with especially the clean up!! Beautiful work man, make us proud!
  4. Ego
    Guest
    Sep 27, 2002, 7:59 AM - Re: Aluminum Helemt Casting Process - by TK-581! #4

    Words escape me . . . I'm simply in awe. Incredible work.

    Makes me feel like a chump for BUYING my stuff!

    Jer
  5. SEEKER's Avatar
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    Sep 27, 2002, 8:02 AM - Re: Aluminum Helemt Casting Process - by TK-581! #5

    very nice. wish i had a place like that to work.

    lucky man
  6. BobaFettish's Avatar
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    Sep 27, 2002, 9:26 AM - Re: Aluminum Helemt Casting Process - by TK-581! #6

    Awesome work. And to think that there were those who said it couldn't (or wouldn't) be done.
  7. secol_FETT's Avatar
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    Sep 27, 2002, 10:48 AM - Re: Aluminum Helemt Casting Process - by TK-581! #7

    man thanks for share, great work

    <|-thumbsup
    _|_


  8. SITH HUNTER
    Guest
    Sep 28, 2002, 10:26 AM - Re: Aluminum Helemt Casting Process - by TK-581! #8

    That was great. I really like the pictures of the process. They allow you to appreciate the work that went into the process.
  9. Member Since
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    Sep 30, 2002, 4:30 PM - Re: Aluminum Helemt Casting Process - by TK-581! #9

    Now that looks hard. The results are that much more impressive now.
  10. Member Since
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    Sep 30, 2002, 4:49 PM - Re: Aluminum Helemt Casting Process - by TK-581! #10

    Dude you are too cool.
    ST
  11. Jodo Kast 3's Avatar
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    Oct 2, 2002, 10:46 PM - Re: Aluminum Helemt Casting Process - by TK-581! #11

    That is just amazing..


    Great job!!!!!



    Jodo
  12. bobagoat's Avatar
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    Oct 3, 2002, 10:47 AM - Re: Aluminum Helemt Casting Process - by TK-581! #12

    wow! cool!!!

    i was wondering how that worked!
  13. Vec Toryn
    Guest
    Oct 3, 2002, 5:04 PM - Re: Aluminum Helemt Casting Process - by TK-581! #13

    Amazing
  14. Member Since
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    Oct 4, 2002, 7:23 AM - Re: Aluminum Helemt Casting Process - by TK-581! #14

    This cant be cheap
    Great work!
  15. natty15d's Avatar
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    Oct 4, 2002, 7:25 AM - Re: Aluminum Helemt Casting Process - by TK-581! #15

    Now that is some cool work

    Nathan
  16. Member Since
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    Oct 4, 2002, 10:58 AM - Re: Aluminum Helemt Casting Process - by TK-581! #16

    That is definitly a labor of love. Strong Work!
  17. Hand-Schaub's Avatar
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    Oct 5, 2002, 1:07 AM - Re: Aluminum Helemt Casting Process - by TK-581! #17

    I'm glad that you are all enjoying the process. It's a great combination of work, art and this great hobby that has infected us
  18. Kr0nk
    Guest
    Dec 8, 2002, 6:56 PM - Re: Aluminum Helemt Casting Process - by TK-581! #18

    Totally outstanding man! What is the overall time of the entire process?
  19. Appolo_50
    Guest
    Dec 8, 2002, 8:00 PM - Re: Aluminum Helemt Casting Process -A real Hand-Schaub! #19

    wow that is very nice!!! how much does it weigh?
  20. Defiler's Avatar
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    Dec 10, 2002, 11:39 AM - Re: Aluminum Helemt Casting Process -A real Hand-Schaub! #20

    Wow, thats amazing. You trully are a Fett fan.
  21. b.fett
    Guest
    Apr 10, 2003, 10:31 PM - Re: Aluminum Helemt Casting Process -A real Hand-Schaub! #21

    I'm speechless..........
  22. mindphunk's Avatar
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    Apr 11, 2003, 1:28 AM - Re: Aluminum Helemt Casting Process -A real Hand-Schaub! #22

    Yeah, great job, impressive. How heavy is it and how much time does it take to make one?
  23. Packrat's Avatar
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    Mar 2003
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    Apr 11, 2003, 10:02 PM - Re: Aluminum Helemt Casting Process -A real Hand-Schaub! #23

    Wow, looks great. I've only worked with sand molds, and just a LITTLE bit. Yours looks fabulous.
  24. Jaster Mereel's Avatar
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    Apr 11, 2003, 10:33 PM - Re: Aluminum Helemt Casting Process -A real Hand-Schaub! #24

    Whew, damn is that an amazing looking helmet! Lots of hard work must have went through that, & just to make 1 helmet - but I think it was well worth every second, looks great!
  25. sithlord23's Avatar
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    Apr 15, 2003, 1:51 PM - Re: Aluminum Helemt Casting Process -A real Hand-Schaub! #25

    that is truly awesome! mucho applause to you

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