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So as I sat there drinking my Red Breast trying to figure out what the hell to make for the swap this year… I looked up and saw the hops wall art I received in last years swap from Tom Regnier. It then dawned on my that I should figure out how to cast hops for a bottle opener handle. I had coworkers at AWW and Stainless Bottle Stoppers were there and sent them back with some prototypes of new ones they're releasing (one is released as of this post).
Casting hops had some unique challenges… Mainly drying them enough. I tried a few methods, but found that the one that seemed to work best for me was to put them in the toaster over for 3 or so hours at about 150. Trial and error for this was about a pound and a half of hops and 5 2×2x6 blanks of Alumilite. You'd be surprised how many hops it takes to fill a mold when they start compressing. I still have a 2×2x3 blank I may make a stand-up opener with.
I had one that I was happy with, but it exploded while buffing it out (the buffer threw it into a wall). So I had to scramble to get the one I sent out done. The new handle was turned down and got 5 or 6 coats of thick CA. I then sanded it to 4000 grit, and put some friction polish on it. I didn't want to take another chance on the buffing wheel
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I also did a cup with a stainless steel liner. I thought it was Sapele but after turning it i'm not sure. The cup was stabilized and the bottom blew out when cutting it off the lathe… -_- Grant was nice enough to not show that picture. Accidents happen though when trying to turn an 1/8" thick hollow form.
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This is the one that never made it
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Rich
Casting hops had some unique challenges… Mainly drying them enough. I tried a few methods, but found that the one that seemed to work best for me was to put them in the toaster over for 3 or so hours at about 150. Trial and error for this was about a pound and a half of hops and 5 2×2x6 blanks of Alumilite. You'd be surprised how many hops it takes to fill a mold when they start compressing. I still have a 2×2x3 blank I may make a stand-up opener with.
I had one that I was happy with, but it exploded while buffing it out (the buffer threw it into a wall). So I had to scramble to get the one I sent out done. The new handle was turned down and got 5 or 6 coats of thick CA. I then sanded it to 4000 grit, and put some friction polish on it. I didn't want to take another chance on the buffing wheel
I also did a cup with a stainless steel liner. I thought it was Sapele but after turning it i'm not sure. The cup was stabilized and the bottom blew out when cutting it off the lathe… -_- Grant was nice enough to not show that picture. Accidents happen though when trying to turn an 1/8" thick hollow form.
This is the one that never made it
Rich
