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:
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: