Last weekend I had a few spare hours so I decided to create a solid aluminum pistol replica with an attachable suppressor. I bought a cheap plastic toy pistol from a 1$ shop, first I carefully separated the pistol into 2 halves trying not to break the plastic casting. After I had the 2 parts separated I filed off the extra bits that might ruin the sand mold. I left 4 plastic pins in one part of the pistol pattern that way the two part would align perfectly. I decided to attach a suppressor to the pistol so I made another sand mold using a separate foundry flask. I also used hard plastic tube (vitamin-c sweets tube) as a pattern for the aluminum casting. For both sand molds I used my green molding sand I was surprised that I didn't have to add water to the sand mixture, it was still good for use since I store the green sand in a closed plastic box.
After finishing the sand mold and the gating system for the molten aluminum I secured the foundry flask cope and drag with clamps. The casting session was quick for this project as there was no need for a big amount of aluminum for such a small casting. Half a crucible of molten aluminum was enough for the pistol replica and the suppressor. I poured the molten aluminum into the sand mold cavity and let the casting cool down for half an hour. The casting was not bad at all, not as high a quality finish as you would get using oil bonded sand (Petrobond) but good enough for homemade green sand. After the metal cooled down I used a reciprocating saw to cut off the gating system.
The next stage was to file clean all the extra aluminum "flash", the casting was good so the cleaning part didn't take too long. After filing the extra aluminum I sanded the aluminum pistol replica and the suppressor. I used my tap and die set to create the threaded holes and a small two sided bolt to secure the suppressor to the pistol barrel. The polishing part is where I never really have too much patience, especially if it is a large object with odd angles. I decided to semi polish the pistol replica giving it a bit more of an authentic look. The suppressor part I polished with more patience ;-)
Anyway here is another useless item that I have created, It will serve as an excellent paper weight.
I am thinking perhaps to place the pistol replica in a wooden box with a glass front and to printed on the glass "IN CASE OF A ZOMBIE ATTACK KEEP IT SILENT" ;-)....If and when I make the box I will add a photo to this post.
