This is awesome. Can't wait to see the finished product.OK. Starting my next set of prints. This will be to print a form to then sand cast in metal. (First test run will be aluminum, and then if that works brass) Who doesn't want to make their own maul?
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I'll print two of these (they can connect via peg holes on the bottom). Then probably a day or two of post work with auto body paint/filler and sanding to get as smooth as possible, then multiple coats of gloss enamel to get smoother. (Smoother the mold form, the less you need to sand/polish the metal when done which is far more work).
Then pack is in casting sand, remove the mold to leave a cavity, and melt/pour in metal.
When all is said and done this should be around a 7lb head to put on a hickory handle probably. And sure, you can say "But why the hell do you need a 7lb maul that looks like an art deco hark head??!?" but I'll ignore you because I don't need that kind of negativity in my life.
I did some pretty basic metal casting not too long ago. I 3D printed some numbers, then took a bunch of copper pipes that my sister had ripped out of her new house when they remodeled it. I cast her house numbers in copper and then put them in a little epoxy cube and put it on a plaque for a housewarming gift. I've mad a ton of ingots that are just sitting around for some future project. Unfortunately, smelting/casting is really rough in the Florida heat, so it's rare I find the motivation.