How to cast wooden blanks.

This how-to process will walk you through step by step the procedure for casting wood blanks to make pens, calls, handles, and more.

Materials List

* Alumilite Clear Resin

* Measuring & Mixing Containers

* Stir Stick

* Digital Scale

* Latex-free Gloves

* Alumilite Liquid Dye or Alumidust

* Worthless Wood or other media

* Pressure Pot w/Air Compressor

* Moldbox (HDPE or Silicone)

* Lathe

* Sand Paper or Micromesh Sanding pads

* Plastic Polish (Novus 3 Step or similar)

Products Used

Step 1 Prepare wood

Before starting, dry and stabilize wood. Using
available saw, trim wood to fit into mold-box. If using scraps, chips, or
fines, simply pour them into your mold box. Note: Moisture in any
substrate will cause bubbles in resin, therefore we recommend that
humidity be less then 5% and/or stabilize wood.

Step 2 Measure resin

Estimate (or use Volume Calculator on the amount of required resin to fill the mold-box
and measure out side A and B per the instructions for the
respective resin. Alumilite Clear is 1:1 mix ratio by weight,
therefore you will need to weigh each side to achieve an
accurate mix ratio. Note: improper mix ratio can result in
tackiness, cloudiness, and soft resin

Step 3 Mix

Combine part A and B together into a mixing cup and
begin mixing. Continue mixing until all striations disappear and resin
is clear. Scrape sides, bottom, and excess resin off stir stick often to
ensure that all resin is mixed. Note: Mixing, pouring, and
pressurization of pressure pot should be done within the stated
working time of the resin.

Step 4 Add pigments

Alumilite liquid dyes or Alumidust can also be
added to the resin depending on the design you are going for.
Alumilite Pearlescent powder can be combined with Alumilite Liquid
Dye to achieve a pearl-effect similar to the many available Alumidust

Step 5 Pour

Slowly pour resin into mold box allowing it to naturally flow
over and around the wood.

Step 6 Pressurize

Place mold inside of pressure pot and pressurize to
40-60 psi. Many pressure pots have their air inlets in the lid, therefore
introduce air slowly to avoid blowing resin out of your mold box. A
deflector can also be placed over the mold box to divert air away
from resin. Hold pressure until resin has hardened and can be
demolded. Resin must cure under pressure to avoid visible air
bubbles in your cured blank.

Step 7 Turning

To ensure that the highest cured properties have been
achieved, it's recommended to allow resin to cure for 12-24hrs.
before turning.

Step 8 Sand and polish

Alumilite resins can be sanded using fine
grit sanding paper or pads. Plastic Polish such as Novus can be used
to polish Alumilite Clear to a high gloss.

Finished Project

Once polished, assemble remaining pieces and you
now have a one of a kind, unique pen, call, or whatever you chose to