Wood pattern for casting iron flowers #4: What remains, is what you want.

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Blog entry by Patternguy posted 03-26-2017 06:52 PM 1156 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 3: Subtracting the inside from the outside yields a flower with just the right wall thickness Part 4 of Wood pattern for casting iron flowers series no next part

Corny title…but it pretty much sums it up.

The wood pieces in the previous posts are what’s known as “plugs”. The red plug represents what the inside of the flower casting will look like. The mahogany plug represents the outside of the flower.

1. Two pieces of plywood are drilled and pinned together. Center-lines are transferred from one to the other.

2. The mahogany plug is mounted on one piece of plywood using the center-lines to locate it.

3. A wood frame is placed around the plug and clamped to the plywood.

4. Two-part urethane epoxy is mixed and poured into the frame.

5. When cured, the plug is removed from the mold. The mold is called a “negative”.

6. The red plug is mounted to the 2nd piece of plywood (on centers). We’ll call this the “male” half.

7. A 3rd piece of plywood, which will become the “match board”, is laid out to what ever flask size the foundry will use to mold the casting.

8. The match board gets a step routed on both sides and the center of the board is chopped out with a forstner bit.

9. A 3/4” hole to drilled thru one side of the board.

10. The negative is clamped to one side of the match board, and the male half is clamped to the other.

11. The entire arrangement is stood up on one side and clamped in a vise.

12. Urethane is poured through the 3/4” hole until full.

13. The negative and the male are removed.

Here is a cross-section of the match board.
(The colors are not accurate but you get the point)

The pattern for a Cooperstown Flower. Perhaps one day I’ll get there and see one of them.

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