Sawing trouble...

[Rusty85]

I've been having some trouble with cutting this head. I need it sliced three times across. One through the mouth, one through the neck, and one right above the eyes. I CANNOT figure out how to get this cut. No places around here will do it (Redding).

I tried using a hacksaw on one casting but that was a disaster as the lines were uneven. I tried to sand the pieces to line up better but it ended up taking too much off the overall length.

Anyone have any ideas?

 

[clonesix]

Material = Plaster? Hydrocal? Ultra cal?

The only thing that comes to mind is to use a metal cutting bandsaw, as it cuts slow and steady. Not sure what it will do to the blade.

 

[Rusty85]

Its made from Resin, more specifically Silcast 2 from Silpak.

 

[division 6]

What about casting it in 3 parts.

Either fix the parts that you have already cut and make new molds off those OR if it's poured through the neck pour part 1 after curing add mold release and pour part 2 than the same for part 3.

D6

 

[00MrNotWrong00]

What about casting it in 3 parts.

Either fix the parts that you have already cut and make new molds off those OR if it's poured through the neck pour part 1 after curing add mold release and pour part 2 than the same for part 3.

D6

Oh that's a much better Idea than mine. If I was doing this I'd do it this way and not the way I was thinking.

Very good Idea.thumbsup

Unless it's hollow, Is it hollow ?

 

[Rusty85]

No its solid. I had one cut a long time ago with a band saw, but its risky knowing this is my last casting. If they cut it wrong it would suck bad...

 

[Chiok]

If you're worried about the cuts going wrong, I'd make a jig for it. A wooden box that just fits the head with a little room around. Wrap the head in cling film or similar, place in the box earside down, then fill the box with expanding foam. Then I imagine you should have a box with a head stuck inside. Then just square it up and send it through a bandsaw. Then free the bits of head from the box, the cling film should stop the foam from sticking, unwrap and you've got your cut head. Then recast it.

I think a bandsaw would be the best tool to cut something that size, that neatly, unless they make a really hot cutting wire. The kerf will mean you lose a few millimetres.

Or, you could recast it in clay, cut the clay one with a wire, then recast the clay? Does any of this make sense?

 

[weaselflinger]

I would use a jeweler's saw.

 

[Rusty85]

Cool, yeah thanks a lot for the replies.

I found a box at the hardware store (Mider Box?). Its square with slits to use as a guide for cutting on the sides. It would work perfectly except that the heads taller than the top of it...

 

[THStudio]

They sale those in various sizes, that should do the trick though. They're usualyl under $5.

Jester from Puppet Master?