Creating a 3D carving to cast

[Router-Jim]

I've wanted to create a 3D casting using the Carvewright to create the model to mold. This presented quite the challenge but thought it thru and will relate how I accomplished it for those who might be interested. I choose a humming bird pattern and mirrored the pattern and carved to 1/2 inch.

[Router-Jim]

Next I needed to release the patterns. I usually run the patterns upside down thru the drum sander to release but the humming bird pattern must by angled and the beak was going to get sanded off if I continued.

You might be able to see that in the picture. I then had to move to the scroll saw to release the patterns.

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[Router-Jim]

The next part was challenging. To mate the two halves. I did this with 1/4 " pegs.

[Router-Jim]

I then packed the sand over the 1st half and flipped over and added the 2nd half and packed with sand the second half and preceded to cast the resulting mold.

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[Router-Jim]

I used a scratch awl in the casting sand to help recreate the lost beak. Here's a couple of shots of the results. I'm pretty happy with the 3D affect. Thanks for reading and I hope you found this interesting. I would appreciate any questions or comments. Thanks Jim

[want2b]

Really cool, your sharing the process with pics helps me understand what all is involved. I think it's great you managed it in your home shop. Not sure I'm ready to jump in but definitely and interesting project.
Thx, Rick H

[Mugsowner]

Nice work, I cut the tabs then use a spindle sander, or on smaller carves a rotary tool with a small sander. If in a tight spot I will use a pointed burr to remove the tab. I could see where a drum sander would remove some of the carve.

[oscarl48]

Super cool. Thanks for sharing.

[Router-Jim]

Thank you Want2b. Mugsowner, and Oscar48. I was using 3/4" HDF with this project. I suppose I could have planed it down to 1/2" and used tabs, but releasing with the drum sander has worked so well in the past and leaves such a nice smooth back surface which I needed to mate the two halves. Like the old saying goes, "there's more than one way to skin a cat".

Again thanks for the comments.