Subscribe
  1. Mar 23, 2006, 1:10 PM - cold cast alu stalk with bubbles? #1

    hi everyone, im working on the bmx potty + filler helmet, in the photo below youll see my custom cold cast alu stalk(hollow). My question is , whats the best way to eliminate bubbles in the resin? Any pointers would save me making hundreds of these "swiss cheese stalks" before i finally get it right, all ideas greatfully received Cheers TF
    Attached Thumbnails Attached Thumbnails dscf0001_29-jpg  
  2. Prymer13's Avatar
    Member Since
    Apr 2003
    Posts
    1,090
    Mar 23, 2006, 1:51 PM - Re: cold cast alu stalk with bubbles? #2

    I thought I had read somewhere that bubbles in resin were caused by fast setting catalysts, or something like that, so a slower setting resin would allow the bubbles to rise and work them selves out of the piece.

    Wish I could be of more help...
  3. MARROW SUN's Avatar
    Member Since
    May 2004
    Posts
    608
    Mar 23, 2006, 2:51 PM - Re: cold cast alu stalk with bubbles? #3

    I would redo the mold and make it to halves. That way when you put them together(at just the right time) your bubbles will be on the inside and not the surface.
  4. Mar 24, 2006, 9:59 AM - Re: cold cast alu stalk with bubbles? #4

    thanks for the tips, i managed to suss out the problem. Too much filler in the resin causes air to become suspended because of the increased viscosity, by reducing the amount of filler or brushing into the mould, air seems to be eliminated.( the stalk with the wire is my third cast with no bubbles) TF
    Attached Thumbnails Attached Thumbnails dscf0001_30-jpg  
  5. Ripcode's Avatar
    Member Since
    Nov 2005
    Posts
    2,268
    Mar 24, 2006, 10:09 AM - Re: cold cast alu stalk with bubbles? #5

    Hmmm... very interesting!

    Are these accurate in size and shape?
  6. Mar 24, 2006, 1:11 PM - Re: cold cast alu stalk with bubbles? #6

    these are accurate in scale in that they are designed to fit my helmet, the dimensions are: full length 180mm/stalk width 9.5mm/thickness 7mm/top slot width 25mm/pivot bolt 10mm/crcle dia. 21mm. the hollow tube will possibly take six 1.5mm cables, these run down to a hollow pivot bolt which is held in place by a hollow allen nut inside the helmet...TF
  7. SOLOCHASER's Avatar
    Member Since
    Dec 2005
    Posts
    343
    Mar 24, 2006, 10:29 PM - Re: cold cast alu stalk with bubbles? #7

    are you going to sell your rf's that has bubbles?
  8. BLUERAM's Avatar
    Member Since
    Apr 2005
    Posts
    144
    Mar 25, 2006, 12:42 AM - Re: cold cast alu stalk with bubbles? #8

    What did you end up doing to cast a hollow stalk?
  9. Mar 25, 2006, 1:31 AM - Re: cold cast alu stalk with bubbles? #9

    SOLOCHASER said:
    are you going to sell your rf's that has bubbles?
    Quite possibly. You could fill the small holes and paint them silver, you'd never know. what helmet have you got....?
  10. Mar 25, 2006, 1:43 AM - Re: cold cast alu stalk with bubbles? #10

    BLUERAM said:
    What did you end up doing to cast a hollow stalk?
    its basically an aluminium tube which runs to a threaded hollow pivot bolt. this is placed into the mould and the open ends blanked to prevent ingress of resin (the mould has resseses to locate the tube end and bolt, this ensures perfect alignment) then you just pour in your resin! TF
  11. GeneralMayhem's Avatar
    Member Since
    Mar 2006
    Posts
    14
    Mar 26, 2006, 6:09 AM - Re: cold cast alu stalk with bubbles? #11

    What kind of resin are you using? Did it come with the aluminum filler?
  12. Mar 26, 2006, 10:15 AM - Re: cold cast alu stalk with bubbles? #12

    I'm using GP polyester resin, the aluminium powder is added before the hardener, the amount is crucial and will effect the finish and consistancy. Good to experiment......TF

Similar Threads

  1. Cold Cast Help..
    By KuCor in forum Jango Fett Costume
    Replies: 5
    Last Post: May 3, 2010, 10:54 PM
  2. Interest thread: Cold Cast/ Carbon hollow stalk
    By terminal fettler in forum Boba Fett Helmet
    Replies: 59
    Last Post: Apr 27, 2008, 3:20 AM
  3. Cold cast question
    By evan4218 in forum Prop Building Workshop
    Replies: 8
    Last Post: Aug 24, 2006, 8:09 AM
  4. Cold Cast Polishing
    By CMAnavy in forum Boba Fett Helmet
    Replies: 2
    Last Post: Jun 21, 2006, 12:44 PM