Casting a Lead Shot Glass!

So the pallet wood guy from Reddit (aka Paul Jackman) sent me this death trap... I sent him one back. This is in response to the assault Paul took on Reddit after posting his video there. People were quite cross that he used pallet wood on something that you'd drink from. I figured there are worst things than pallet wood to make a shot glass out of....

I built a simple box out of prefinished plywood scraps and hot glue to act as a mold box. My hope was the prefinished plywood would not stick to the plaster. It worked great. To protect the original shot glass and make removal easier, I coated it with Vaseline being careful to avoid the bottom. I put a small dab of hot glue on the bottom of the glass and stuck it to the bottom of the box. The bottom of the box will become the top of the mold and the bottom of the glass becomes the "sprue" (fill hole)

I mixed up a batch of plaster of paris with the boss, 2 parts plaster into 1 part water. Once it was thoroughly mixed together and all the lumps were broken up I shook the bucket and tapped it on the bench to remove the majority of air bubbles. We poured the mixture into the mold until the plaster came up just slightly over the top of the wooden shot glass. The surface tension kept it from pouring in. After that had set up for about 20 minutes I used the back of a sharpie to create 3 divots on the surface of the plaster. These are registration points so I am able to line up the two halves of the mold.

After an hour the mold was sufficiently hard enough to move on to the second pour. I coated the existing plaster of paris with a thin coat of vaseline. This stops the two halves from sticking together. I poured in the plaster, shook out the air bubbles and let it sit for the night. All the tapping did break the bond on one edge of the mold and that's why you see tape on the mold when I take it apart. It probably wasn't needed, but better safe than sorry!

The next morning I cracked the mold apart, recovered the wooden shot glass and put the two halves of the mold in my toaster oven. I slowly ramped up the temperature to 400 degrees F over several hours to prevent the mold from cracking. I cooked the mold for over 12 hours but it could have used even more time. Before casting the lead I lowered the temperature of the mold to 350. The mold was hot when I cast the metal.

I poured some lead into a ceramic melting dish, fired up my homemade propane furnace and melted the metal. For flux, I used a small piece of beeswax. The flux reduces oxidization and forces the tin and lead to mix back together if separated. Maybe I just like making a giant fireball... you'll never know. I poured the freshly fluxed and scraped lead into the mold and it bubbled a little as the remaining moister in the plaster was cooked off. I was afraid there would be air bubbles left in the cooled lead, but thankfully there wasn't. If there were bubbles, I would have made a new mold and dried it longer. I still might do that...

I broke the mold apart, since plaster like this is only good for one casting, and found a perfectly formed lead shot glass! I filed the mold lines off and used a steel brush to give it a light polish.

It weights exactly 14 times as much as it's wooden twin!

I made a simple crate out of the scrap wood from my last video and filled it with wood shavings for protection.

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= Links To Tools Used =
Hot Glue Gun: http://amzn.to/2iRVqqL
Hot Glue: http://amzn.to/2iU5y2a
Plaster of Paris: http://amzn.to/2inqaMk
Vaseline: http://amzn.to/2A88TyW
Sharpie: http://amzn.to/2iTYOBg
Lead: http://amzn.to/2A03EQU
Beeswax: http://amzn.to/2z8RbLH
Melting Dish: http://amzn.to/2zqPcFl
File: http://amzn.to/2iRPlKO
Wire Brush: http://amzn.to/2zpCUx7
Letter Stamps: http://amzn.to/2w5fKpm
Gorilla Tape: http://amzn.to/2zbiYgu
CA Glue: http://amzn.to/2A0Lj6q
Accelerator Spray: http://amzn.to/2zd6Zz1

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Видео Casting a Lead Shot Glass! канала dustin penner