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Cloning a Record Bar Clamp Jaw, By Casting a Duplicate

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Forum topic by poopiekat posted 04-24-2020 03:49 PM 265 views 0 times favorited 2 replies Add to Favorites Watch
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poopiekat

4811 posts in 4614 days


04-24-2020 03:49 PM

Topic tags/keywords: resource casting epoxy cloning parts

My favorite Bar clamps are these Record #133’s. They are crazy strong, but I removed a retaining bolt, allowing one jaw to slide off and get lost. Using polysiloxane as a mold material, I created this mold:

Using a jaw from an identical clamp, I filled the mold halfway. The idea was to create a clamshell. Once the bottom half of the mold cured, a spritz of silicone mold release was sprayed onto the mating surfaces

Then the top half of he mold can be poured in

Works should be pressurized to 30 psi, if little bubbles in the epoxy is a problem:

Mold can then be separated once cured. The original part can be removed and Ecopoxy can mixed, tinted and poured in. I made one red and one blue… the blue one was a ‘fail’.

Red one, de-molded and flash removed:

Red one installed on the clamp, an original clamp behind it.

There ya go! The purpose of this thread is simply to demonstrate the use of epoxy resin to create missing parts on your tools. I am not advocating this as the BEST way, or the ONLY way to do it. It is a fascinating method to conjuring up missing pieces. This is the same products and techniques used by those slab guys who fill in voids on tables and mantles.

Next, I will be casting the center section of some bit braces, where it has to be done in place. The original wood grip was slid on the crank before it was bent, so I think I can restore a couple of braces back to service with a cast handle to replace the lost wooden original. I can’t think of any other way to do this.

Enjoy!!

-- Einstein: "The intuitive mind is a sacred gift, and the rational mind is a faithful servant. We have created a society that honors the servant and has forgotten the gift." I'm Poopiekat!!


2 replies so far

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Foghorn

569 posts in 266 days


#1 posted 04-24-2020 04:09 PM

That’s pretty cool. I was half expecting to see you fire up a mini blast furnace and make up a sand mold. It would certainly be within your abilities. :)

-- Darrel

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poopiekat

4811 posts in 4614 days


#2 posted 04-24-2020 04:18 PM

Thanks, Darrel! Kevin wondered whether I would resort to the “Lost Wax” method of casting. Sure enough when I couldn’t drive out the dummy bar despite generous spraying of silicone, my second attempt with the red epoxy I used a brushed-on coating of paraffin. Voila! It came out easily with a bit of heat.

There was an old man in my neighborhood who made his own furnace. He melted down aluminum cans and made sand molds of all kinds of coathooks, gate latches, and art objects. I used to go to his yard sales, where he sold his creations, but alas the old guy passed away recently. Those hand skills are fast disappearing these days.

-- Einstein: "The intuitive mind is a sacred gift, and the rational mind is a faithful servant. We have created a society that honors the servant and has forgotten the gift." I'm Poopiekat!!

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