Recreating the vintage red plastic handle with a mold casting

RobertTaylor · Post by **RobertTaylor** » Sat Mar 28, 2009 3:16 pm

i have an easy solution. i have a few of the old red style that i would trade.

anmius · Post by **anmius** » Sat Mar 28, 2009 3:36 pm

The easiest way to make a mold of the "old style" handle grip is to use "RTV" rubber (Room Temperature Vulcanization) to make the mold. Into that mold with the bare handle inserted, your new material can be poured and you will get an exact reproduction with a reasonably good finish although about 1-2% smaller due to shrinkage of the RTV rubber. The problem will be finding the "right" plastic to make the new handle grip. I have used this process many times for making a mold for metal casting (pewter, zinc, tin, lead, etc.) but not for plastic.

bucksaw · Post by **bucksaw** » Sat Mar 28, 2009 4:00 pm

I wouldn't bother making mold that is a match. I'd just make a square or octagon mold and suspend the handle in the mold, pour the plastic in. Let it harden and then machine the handle down to size using the same techniques you used to polish the aluminum. I have no idea if it would work...but it might be worth messing around with if you can fine the plastic.

RobertTaylor · Post by **RobertTaylor** » Sat Mar 28, 2009 4:26 pm

bucksaw is on track. guys in the pen turners forum cast blanks all the time. casting, then turning would be no problem. but (there's always one of those) do you really want to spend a $100 to make something that is readily available? just my $.02 fwiw

ok i know people will want to know why i said a $100. make a mold, cheap (buy a white umhw cutting board). buy some resin, (now we're talking some money), oops got to make it red. now we need some pigments. go to woodcraft, craft suppies usa, or rockler. basic set is about $20 plus shipping. then if you don't cast other stuff the left overs will be thrown in the trash. (short shelf life once opened). oh yeah, don't forget about air bubbles in the casting. but (yeah another one of those) there are always ultrasonic vibrators, pressure pots and even vacuum chambers. one of those should work.

dusty · Post by **dusty** » Sat Mar 28, 2009 4:47 pm

bettyt44720 wrote:bucksaw is on track. guys in the pen turners forum cast blanks all the time. casting, then turning would be no problem. but (there's always one of those) do you really want to spend a $100 to make something that is readily available? just my $.02 fwiw

ok i know people will want to know why i said a $100. make a mold, cheap (buy a white umhw cutting board). buy some resin, (now we're talking some money), oops got to make it red. now we need some pigments. go to woodcraft, craft suppies usa, or rockler. basic set is about $20 plus shipping. then if you don't cast other stuff the left overs will be thrown in the trash. (short shelf life once opened). oh yeah, don't forget about air bubbles in the casting. but (yeah another one of those) there are always ultrasonic vibrators, pressure pots and even vacuum chambers. one of those should work.

Good sales pitch. If I need a red handle, I'll look you up.

RobertTaylor · Post by **RobertTaylor** » Sat Mar 28, 2009 6:09 pm

yeah, after reading back through my last post it sure does sound like a sales pitch. i have none for sale. i have only the ones for my machines. i was merely trying to help a guy by swapping for what he wanted. i've repainted ugly machines with whatever colors i have handy at the time, but have not restored a machine to it's original beauty. i just like a nice working shopsmith to use, ain't fussy about the details.

fjimp · Post by **fjimp** » Sat Mar 28, 2009 7:33 pm

Ebay sometimes has the red handles for sale.

JPG · Post by **JPG** » Sat Mar 28, 2009 7:44 pm

fjimp wrote:Ebay sometimes has the red handles for sale.

I picked up a couple that way, BUT they had carriages attached to them.

fjimp · Post by **fjimp** » Sat Mar 28, 2009 7:54 pm

Actually I noticed just the red handle in the last day or two.

dusty · Post by **dusty** » Sat Mar 28, 2009 7:56 pm

JPG40504 wrote:I picked up a couple that way, BUT they had carriages attached to them.

I really like this approach, JPG. Buy control handles on ebay and harvest the excess parts off of them for use elsewhere.

she: What did you buy on ebay today, honey?

he: Oh, not much. Just some really hard to get control handles that I have been needing for a long time.

she: What's all that other stuff?

he: I don't know, just some stuff he sent along with the handles.