Post by bronto on Sept 10, 2019 16:02:56 GMT -5
I'm a total newbie to making molds and casting parts, so THANKS(!!) in advance to anyone who can provide some advice on how to proceed with my project.
In short, I want to make a mold to cast a mounting plate for a commercial LED light fixture (with a flat back) that mounts to a corrugated metal building panel that has a wavy profile. What I am thinking of is similar to what I found on garagejournal.com (see post #14).
Here is a pic of the example of the finished mounting base he made from body filler: Light Mounting Base Example.pdf (111.1 KB)
and here is a pic of his form: Light Mounting Base Example Form.pdf (107.07 KB)
The back of my light fixture is 18" wide by 7" tall and, as noted previously, my metal panel is corrugated and has more undulation than the example pics show. Similar to the example, I'd like to make the mounting base about a 1/2 to 3/4" larger on all sides, so my finished mounting plate will be 19-1/2" wide X 8-1/2" tall and varying between 1/2" and 2" thick.
As I have 11 light fixtures to make bases for, I thought it would be easiest to make a prototype mounting plate using the garage journal "scrap siding and plywood" form method, use the prototype plate to create several (say 3 or 4) reasonably identical molds, and then cast duplicate plates 3 or 4 at a time.
Questions:
Thanks!
Mark (aka Bronto)
In short, I want to make a mold to cast a mounting plate for a commercial LED light fixture (with a flat back) that mounts to a corrugated metal building panel that has a wavy profile. What I am thinking of is similar to what I found on garagejournal.com (see post #14).
Here is a pic of the example of the finished mounting base he made from body filler: Light Mounting Base Example.pdf (111.1 KB)
and here is a pic of his form: Light Mounting Base Example Form.pdf (107.07 KB)
The back of my light fixture is 18" wide by 7" tall and, as noted previously, my metal panel is corrugated and has more undulation than the example pics show. Similar to the example, I'd like to make the mounting base about a 1/2 to 3/4" larger on all sides, so my finished mounting plate will be 19-1/2" wide X 8-1/2" tall and varying between 1/2" and 2" thick.
As I have 11 light fixtures to make bases for, I thought it would be easiest to make a prototype mounting plate using the garage journal "scrap siding and plywood" form method, use the prototype plate to create several (say 3 or 4) reasonably identical molds, and then cast duplicate plates 3 or 4 at a time.
Questions:
- Is this a good approach or should I simply make 11 forms using corrugated scrap and plywood (or re-use a corrugated scrap and plywood form repeatedly)?
- If making a mold is a better approach, what materials would y'all recommend (note: the plates need to be weatherproof as they will be mounted on the exterior of a building)?
- Given the size of the plate, how much mold and casting material will I need?
- Any other words of wisdom or suggestion on how to proceed?
Thanks!
Mark (aka Bronto)