Petrobond sand mold in progress.

Cast aluminum from existing pattern. Petrobond sand mold.

Aluminum mesh was 3D printed and cast using "lost wax" ceramic shell. Arch is 3D printed Bronze fill.

3D printed and cast in iron using "lost wax" in ceramic shell.

My first machining project; done for the Friends of the Cumbres & Toltec Scenic Railroad. Turning down a 1 1/4" wrought iron bar for threading. This will become the hand-brake mechanism on a 1930's tank car.

The square taper is cut to match an existing hand wheel.

Test fit of the had wheel on the tapered shaft.

Cutting a keyway for the ratchet wheel.

First bore with a twist drill. A boring bar will be used to clean up the bore and size it properly.

Turning down the first end. Both bushings will come from the same bar stock.

Barstock was split using a parting tool, then each bushing flange was trued to a 3/8" thickness. These will be welded in place.

Made from plastic, foam and tie line. Done as a demo for Scenic Technology. I fabricated and painted this in one 55 minute class period. The class then has to pick, and make a weapon using plastics.

Made from plastic, foam and tie line with a cast hot melt glue rosette. Done as a demo for Scenic Technology. I fabricated and painted this in one 55 minute class period. The class then has to pick, and make a weapon using plastics.

Made to replace missing parts for the department's stage combat stock.

Castings de-burred and polished, ready for drilling.

Each blade is hand forged and requires filing of the cross guard for a tight fit.

With newly a wrapped grip and the pommel threaded the sword is ready for use. I have also de-burred and polished the blade.

Some of the sample molds and finished pieces made as class demonstrations. Students start with hardware store materials like plaster, and caulk then move on to catalyzed urethanes and silicone.

As a volunteer project, I cast a set of replacement bridge washers for the Cumbres & Toltec Scenic Railway that runs between Colorado and New Mexico. This is the repaired original used as a pattern.

A silicone pancake mold set in its plaster mother.

For efficiency multiple urethane patterns were cast from the original.

Made to cast 4 washers simultaneously. Note the removable piece that creates gates in the drag.

The mold in process. The mold is keyed for proper alignment and the gate pattern is ready to come out and be drilled to create a sprue.

One of the duplicates ready for clean up.

Ready to be shipped and installed. These are in use on the Railway.

Above are some of the parts removed to be used as patterns for another casting project for theFriends of the Cumbres & Toltec Scenic Railway.

This is one of the three main sheaves cast for the railway's derrick crane. This was done with a seven core resin bonded sand mold. It will get some machining before use.

The sheave ready to be milled out for a stainless steel bushing. Machining done by volunteer Russ Hanscom.

The bushing pressed in an getting trimmed flush. Machining done by volunteer Russ Hanscom.

Here are the finished sheaves installed and in use in the main blocks for the boom.

I am a hobby blacksmith and thus occasionally make decorative pieces, some for shows, some for myself.

A personal project.

Designed for my parents house, these are forged steel done in an art nouveau style.

Also designed for my parents house, these are forged steel done in an art deco style.

My first casting project for the Friends of the Cumbres & Toltec Scenic Railway involved making replacement parts for caboose stoves. This is the mold for replacement doors.

One fresh out of the mold.

Ready to be drilled and installed.

The other missing piece from many of the railway's stoves was the fire grate. Because they are so rare another voluteer, Craig McMullen made a wooden pattern I could use instead.

Fresh from the mold

Cleaned up and ready for service. These castings are in use in three of the railway's pot belly stoves.