Recreating a vintage design 

Some file handles used to be made in cast iron. In todays video I'll be making my own version in silicon bronze. I started by creating a model in Fusion 360. Then I 3d printed the models and used them to create sand molds. I cast these in two pieces and then welded them together so that's why I choose to use silicon bronze (Everdur). Once I was finished welding them I spent many hours cleaning up the castings. I machined the clamps using my benchtop milling machine.
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Casting equipment
PetroBond amzn.to/4bZJqsJ
Crucible salamander amzn.to/4eo1vSW
Crucible lifting Tongs amzn.to/3Vtc26G
High heat Gloves amzn.to/3XqPiai
Leather Jacket amzn.to/4chpUaU
Boot Covers amzn.to/4aZ1G4o
Boots amzn.to/3XpFmxz
Casting Flasks amzn.to/3Rtj4XT
Graphite Molds amzn.to/3VkiIUK
Blow torch amzn.to/3z3Rkms
Respirator amzn.to/3zbFUNq
Face shield amzn.to/4b47XM3
ToAuto Furnace amzn.to/4epMeRz
Propane Furnace amzn.to/3yVQIz9
3d printing FDM
Filament amzn.to/4coyVPQ
3d printer Ender amzn.to/3L58YsZ
3d printing Resin
Siraya tech castable resin amzn.to/4b95n7w
Elegoo resin amzn.to/3XrASGY
Resin Printer Mars 4 amzn.to/3RsL6mw
Belt Grinder
Grinding Belts amzn.to/3RsTySM
Surface conditioning belts amzn.to/4eicD41
Trizact belts amzn.to/3RuW0bg
Belt Grinder Accessories
Grinding Belts amzn.to/3RsTySM
Surface conditioning belts amzn.to/4eicD41
Trizact belts amzn.to/3RuW0bg
6” grinding wheel amzn.to/4b3NF5h
Welding
Kidskin welding gloves amzn.to/3VstSXu
Prime Weld machine amzn.to/3KMeXCQ
Metal finishing tools
Nevrdull amzn.to/3XwyVsu
Liver of Sulfur amzn.to/3XkFCOs
Protectaclear Clear Coat amzn.to/3XrBjkA
Scotch-brite Wheels amzn.to/3KI6v7B
Metal Files High Quality amzn.to/4eifrOB
Die grinder discs Benchmark abrasives amzn.to/4esof4v
Dremel - rubber polishing bits amzn.to/3KKvAi5
Dremel - Wire brushes amzn.to/3yYtQiu
Simichrome Polishing Compound amzn.to/3xapnZM
General
Wilton bullet bench vice amzn.to/4ckifIV
Bandsaw blades amzn.to/3XkmGPT
JB weld amzn.to/3xapGno
Super Glue amzn.to/3VISP2i
Shop Lights amzn.to/3xmMVur
Loc-line shield amzn.to/45v7Nfx
Smoke purifier amzn.to/3XoCMI4
Some of my favorite tools of the year
Makita Blower amzn.to/4c43LNK
Mini circular saw amzn.to/3VnWykp
Makita blower small amzn.to/4eCxFKT
Ratcheting screwdriver amzn.to/3KQUc8J
German pliers amzn.to/3xiRKou
Dremel cordless amzn.to/45ofDrt
Camera Equipment
Canon 6d II amzn.to/4erxUbi
Lights amzn.to/3xjzMSK
Rode Mic amzn.to/3XkFkHm
Canon 50mm stm amzn.to/3VJ3EBu
Canon 24-70 f2.8 amzn.to/3z340dn
All of the links above are affiliate links. This means that, at zero cost to you, I will earn an affiliate commission if you click through the link and finalize a purchase.
Intro 0:00
Making a pattern 0:15
Making sand molds 1:39
Silicon bronze 3:03
Melting bronze 3:37
Opening Molds 4:20
Cleaning up castings 4:58
TIG welding 6:48
Making clamps 7:40
Finishing 9:50

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