I had tried earlier casting some fairly massive strap ends with a hook on one and an eye on the other, with quite poor reults. After finding these images and having a discussion with my casting guru, I went back to the drawing board. The best part about this design is that, as long as the strap ends are symmetrical, only one model is needed for both. I started with a basic tapered rectangle cut out of 22ga steel, glued to a larger piece of styrene card to support the edges of the model. I drilled two holes through the steel, and glued in two cut down nails to serve as integral rivets. As the loop would be perpendicular to the parting line of the mold, I needed to build it around a dowel. I drilled a hole in the dowel and glued in a small nail, which I hammered flat to better secure it to the rest of the model. I stuck everything together with a rough first layer of epoxy putty, then came back and added surface details in the same material. The design was pretty much made up as I went along.
The pieces were sand cast, with another dowel set into the cavity after the model was removed to support the loop. After casting, the dowel was removed. As my casting sand isn't the finest, some detail was lost, but at the same time the surface imperfections on the original model were smoothed over. The final pieces required some cleaning, but turned out fairly well. I still need to design and cast the S-hook, but that should be fairly simple in comparison.
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2007-01-04 04:28 am (UTC)