Can someone please give me metal casting advice?

[Mojo_Turbo]

Ok, this is NOT about prop building, but being a member here - the question is still for you experts.....

A little story....

My mom has these antique metal coasters - they are flat round circles with a intricate design on one side and blank on the other. She has a circular stand that they all fit in - and there has always been one missing. So they rest in the stand a little low [since one is missing]. They are not made of silver... they are like some other "silver" metal.

I want to make a cast of one and make her a replacement one. So I need to make a cast of something "coaster size."

I have already done some preliminary research on the web, but the problem is when you look up "casting metal" you get so many options and opinions and just like the internet...it's almost too much information.

I just need someone to say.... "here is what you need" from start to finish.

Maybe these instructions already exist on RPF and I can't find them.

What materials do I need [exactly - brand names etc]
How many steps
Do I need a smelter?
Or should I find a local hobbiest?
Is my idea stupid and should just give up?

Remember I want to only make 1, make it cost effective, and there is some detail - but only on one side.

You can even PM me....

Thank you in advance for reading this rambling....

 

[Contec]

It will help if you can post a picture of the item.

 

[Mojo_Turbo]

I will try, but she lives across town and I am trying to do this as a surprise....

 

[fuelish]

Give this site a try
http://www.backyardmetalcasting.com/
Looks pretty good for someone trying to cast on a budget.

 

[CustomCreations]

HI,
You can get a heavy duty silicone rubber which is maroon in colour from Alec Tiranti, for example:
http://www.tiranti.com/subdivision_...+-+Mouldmaking&Subcategory=51&Subdivision=173

You could make a silicone mold of an original maybe?

You can buy a low melt pewter type metal to make a duplicate from this silicone mold....
It might not be as strong perhaps, but would certainly work beter than resin etc.....

 

[SG Merc]

Another method is cold casting. This is where you cast with liquid resin with metal powder mixed in.

 

[Fetts.Sobriquet]

How to Cast small metal parts

 

[Conqueror_Worm]

If the originals are not made of silver or pewter I would guess that they are pot metal. Pot metal (a zinc alloy) melts at a low enough temp that you can melt it in a pot on the stove (no furnace needed).
You say that they are blank on one side, this could mean that they were cast in an open face mold, the same way creepy crawlers are made. This would be very easy if you can get a plaster mold of the detailed side.
If you use an original to make the mold then the one you cast will be slightly smaller, but it shouldn't be noticeable on such a small piece.

 

[Dimclay]

How about this ??
http://www.youtube.com/watch?v=oQppW67xtLg