Subject: Manual Aluminum Molding

From: Robert Bowen <[email-masked]>
Date: Mon, 10 Jun 1996 11:29:28 -0700

I need advice and info. to design tooling and hand mold an Aluminum prop
spinner for a RC model.  My idea is to cut an outside mold into a
1 1/2 inch steel dowell for the outside shape and cut a plunger for 
the inside shape.  The spinner would be thin at the nose and thicker at 
the base which can be machined after molding to accept a base part as 
required.  That is if it stays in the mold on seperation.  This could be
assured by a thick washer attached to the mold with neg. draft to
hold it on initial separation,followed by removal of the washer item.

QUESTIONS:
A.   which alloy?        B.   what mold release?

C.  What temp?  (intend to soak total setup incl Al to 300 or so)

D.  Can pressing of this small setup be done in a vice>

E.   I plan to polish the mold to mirrow finish!  Good or Bad?

F.   What about diferences in coef. of expansion?

 G.   Am i nuts thinking it can be done?  If so, why not wheel rims,
  car frames etc,etc.  The big guys do it, why cain't we amateurs.
It sure presents some interesting machine work.
All replies welcome.  Post or e-Mail me at [email-masked]