Machining Help

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Tikka300

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I realize this is a little off topic but I'm looking to have the below mold (like the bottem picture) made for making duck decoy anchors out of lead. The mold can be cut out of steel or aluminum at least 10mm thick and needs to be cut 3.5mm deep into the stock. I'm hoping someone can tell me what I should expect to pay for this mold and what type of place would be willing to do this type of work.

AceDecoyAnchorFORMmetric.jpg


mold.jpg
 
If that is a one piece mold, you are probably looking at minimum shop charge, probably 1/2 hour, to make one. I think shops are charging in the range of $70 - 80/ hr so probably $40 for one mold but a lot less (each) for several. I am also guessing that you probably have some pretty loose tolerances on dimensions which also save money if making several.

cheers mooncoon
 
Got a router? Make it out of a piece of hardwood. The first few pours will charcoal the cavity. See how many you can get out of one cavity before it is toast, you may be surprised.
 
Maynard has an excellent idea. But use dry wood, and also a non-oily wood. Maple, oak or hickory would probably let you cast at least a dozen 'hooks' per mould, as long as you poured as soon as the lead went liquid.
(that is, don't let the lead get too hot)
 
Perhaps we are jumping the gun a little here, this mold consist of “two” mating parts, with the design cut into two separate blocks of aluminum.
It would take a longer then ½ an hour to make this, and there is a little more cost involved here then “next to nothing”.
You would need the 5/8” and ¼” ball mills, a piece of 1/2” alum plate, a decent mill and a couple hours to set up and complete this project.
 
Following up on Maynard's suggestion if you can make it out of hardwood using a router you should be able to make it out of aluminum. There are cheap Chinese carbide cutters out there that would work. Just take shallow cuts and be sure to use a face shield.

I shape a lot of aluminum with carbide tools and join pieces with stainless rivets.
 
Al Flipo said:
Perhaps we are jumping the gun a little here, this mold consist of “two” mating parts, with the design cut into two separate blocks of aluminum.
It would take a longer then ½ an hour to make this, and there is a little more cost involved here then “next to nothing”.
You would need the 5/8” and ¼” ball mills, a piece of 1/2” alum plate, a decent mill and a couple hours to set up and complete this project.
Click to expand...

Huh? :p Looks to me like a double cavity/2 at a time deal, I don't see how a closed cavity mold would apply here ;)
 
Ardent said:
Huh? :p Looks to me like a double cavity/2 at a time deal, I don't see how a closed cavity mold would apply here ;)
Click to expand...
You got it, the photo shows a mold for 2 at a time. Thanks again for all the good ideas.
 
You could be environmentally conscious and use cerro-tru instead of lead.

That would also have the advantage of having a much lower melting point - so much so that you could then make a permanent mold out of teflon or delrin that would be self-lubricating.

Also, whatever material you are using, consider making the mold out of several pieces that are cut out using a band or jigsaw and then joined. It is much easier to get the castings out that way too.

I'll add an image in a little bit.
 
Gun5tuff said:
Following up on Maynard's suggestion if you can make it out of hardwood using a router you should be able to make it out of aluminum. There are cheap Chinese carbide cutters out there that would work. Just take shallow cuts and be sure to use a face shield.

I shape a lot of aluminum with carbide tools and join pieces with stainless rivets.
Click to expand...

True.
As a metal fabricator, I have cut Aluminum plate 3/4 inch thick with a skill saw. You do need the carbide blades though.
 
If you don't have to make hundreds of them you can make the mold out of high temperature silicone rubber. Put the part in a box, add the sprue, pour in the rubber compound and let it cure. Cut the rubber block open and remove the part & sprue, instant mold.
The rubber will easily take the heat from melted lead. A rubber mold will last for hundreds of pours, but it isn't as easy to handle in production as a metal mold, unless your go to really high production methods like cetrifugal casting.
 
Sounds like a lot of expensive fuss for something you can make in a small cat food tin and some wire. If you start thinking about having anything machined you're looking at long dollars per hour. You'd likely be able to find something heavy enough in Pricess Auto too.
 
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