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Lollipop Struts Casting Process.  Rate Topic 
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 Posted: Mon Jun 7th, 2021 03:14 pm
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Louis Luu
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A while back, George wanted to know the process I go through.  I thought I go ahead and start a new post here for the process for miniaturizing the Lollipop struts for the 8 inch open commutator project.  Pictures will be posted soon.  Need some coffee in me first. 

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 Posted: Mon Jun 7th, 2021 03:32 pm
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Louis Luu
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Start off by doing a really good degreasing and removing some of the Japanned paint off to remove unevenness due to drips and removing burrs from original casting.  More pictures to come as I walk through the process.





 

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 Posted: Mon Jun 7th, 2021 03:47 pm
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Louis Luu
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Next step.  Make sure the boss of the house is asleep and find a place to work at....pantry sink.  I use this 3M bondo to fill in the crevices that will cause casting problems...these are usually rivet/screw holes.  Let it sit in the sink for 1 hour before throwing into the oven at 200 F to fully cure for 30 minutes and let cool.  Again...make sure the boss is asleep.




Last edited on Mon Jun 7th, 2021 04:01 pm by Louis Luu

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 Posted: Mon Jun 7th, 2021 03:52 pm
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Louis Luu
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Why 3M bondo...was on sale and I bought too much of it and have to use it up...horrible stuff.  Don't forget to do the stick.  Make sure to have an awful show the boss doesn't not like turned on...so you don't get disturbed while working.




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 Posted: Mon Jun 7th, 2021 03:53 pm
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Louis Luu
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Don't forget to tell the boss what you are watching...too late. Now she is sitting in the room you are working in. Remember, don't forget to announce what you are watching and make sure she hates it. I like VINWiki.

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 Posted: Mon Jun 7th, 2021 04:05 pm
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Louis Luu
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Need to move to another work area...forgot to tell the boss what I was watching. I can't stand that drama crap the boss watches. Make sure to log off AFCA before leaving the work area.

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 Posted: Tue Jun 8th, 2021 12:12 am
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Louis Luu
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After sanding to remove excess bondo.




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 Posted: Tue Jun 8th, 2021 12:17 am
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Louis Luu
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Self etching primer is used on the first coat so the primer filler in the next step sticks better.  Need to sand and make smooth again before laying down another coat of primer filler to build up coat to fill in crevices.






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 Posted: Tue Jun 8th, 2021 02:39 am
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Louis Luu
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I'll work on smoothing out the initial etching primer follow by filler primer to compensate for shrinkage. Then follow by a coat of acrylic.

Then a shell will need to be made to either pour a resin or polyclay. This will be cut and modified for the 8 inch R&M open commutator struts. I will make both struts for mini-lollipop and mini-vane oscillator. The hard part will be fabricating the struts.

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 Posted: Tue Jun 8th, 2021 02:21 pm
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Louis Luu
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Another day, another internet connection issues. AFCA is having problems connecting.

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 Posted: Tue Jun 8th, 2021 10:44 pm
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Louis Luu
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There was still some uneven high and low areas...wet sanded to make it even.  Follow by another coat of etching primer.  Wet sand again tomorrow.  Followed by another coat of filler primer on top tomorrow.





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 Posted: Wed Jun 9th, 2021 12:32 am
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Tony Clayton
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A MAZE ING

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 Posted: Wed Jun 9th, 2021 03:31 am
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Louis Luu
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Thanks Tony. The second coat of etching primer went on much smoother. Will do another round of went sanding tomorrow followed by a light coat of etching primer and primer filler on top directly on top.

This will then need another round of light wet sanding and acrylic paint on top for durability. From there, I make the shell to pour the resin. Resin may be a problem due to the angles of the struts...may need to do polyclay shell instead.

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 Posted: Wed Jun 9th, 2021 03:46 am
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Louis Luu
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I need to cast two sets of struts for my 12 inch Lollipops I have laying around. While I normally adjust for shrinkage...this one will be a pain. The width will not be an issue but length shrinkage maybe. I will use the resin or polyclay and cut to length for the mini-lollipop/vane project.

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 Posted: Wed Jun 9th, 2021 02:21 pm
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Louis Luu
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Today, I recommend watching Rabbit's Used Cars...the boss hates it.  Heck, I'm not even watching it.  Will be in the backyard wet sanding.  She hates it so much, pretty much leaves me alone.  In between drying, I will be opening up another fan I picked up from down under, a Webley Fan.  These fans are way cool and under price in my opinion...but that is just fine with me.  Currently have about 10 of these fans along with two of the older ones.





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 Posted: Wed Jun 9th, 2021 04:27 pm
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Jim Dunn
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Incredible work on the mini lollipop Louis๐Ÿ‘I have a soft spot for the webley fans too.๐Ÿ˜Ž

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 Posted: Wed Jun 9th, 2021 04:34 pm
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Louis Luu
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Jim...good to hear from you. I will hold onto your badge and send along with the gearbox when ready...saves on shipping. Shipping right now from Australia is really fast...in about a week.

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 Posted: Wed Jun 9th, 2021 06:00 pm
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Louis Luu
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Wet sanded excess off to get an even surface.  Followed by last round of etching primer.  Need to let dry before doing the other side...propped up with pennies....surface nice and even.  Primer filler will go directly on top.  Followed by more wet sanding tomorrow and acrylic paint for durable finish before making the shell for casting.











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 Posted: Wed Jun 9th, 2021 07:24 pm
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Louis Luu
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Primer filler follow by more sanding to even the layer and more filler to build up layer.
Tips:  use a small q-tip to fill in small areas.  Make sure to let it fully cure before spraying more...lots of degassing and cracking.  I generally like to do another round of sanding before laying down another layer...get better smoother result.  Will let it cure fully...tomorrow another round of wet sanding and laying down another layer of primer filler.  Overall buildup should be around 2% more than the original.  Last layer will be acrylic for durable finish.  The stick will need the lettering area exposed....tape and Jasco with q-tip does the trick and wire brush with running water.










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 Posted: Wed Jun 9th, 2021 07:28 pm
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Louis Luu
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Anther tip for smoother sanding...I like adding soap to a bucket of water...makes it easier to sand.

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 Posted: Thu Jun 10th, 2021 11:19 pm
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Louis Luu
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Almost there.  Laid down enamel paint...probably take a day to fully cure.  I still need to do the pendulum piece.  Once done, I will make a shell and cast in polyclay and start trimming it down for the mini-lollipop.  This is probably the hardest part of the project.  Excess paint on the stick will be remove to reveal decal...will do that tomorrow.  Process involves tapping off section to protect the paint and applying Jasco with q-tip.  This will remove the paint.  I will take pictures of this process tomorrow.
Surface is even and smooth...makes casting an easier process.












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 Posted: Fri Jun 11th, 2021 12:50 pm
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Louis Luu
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Another day, another internet connection issue.

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 Posted: Sat Jun 12th, 2021 02:49 pm
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Jim Dunn
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Thanks Louis.. awesome work ther mate.No stress ๐Ÿ˜Ž much appreciated.. let me know total costs please.. all your work and help is really appreciated.

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 Posted: Sat Jun 12th, 2021 03:12 pm
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Louis Luu
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I will go through the badges tomorrow and toss out the bad ones.

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 Posted: Sun Jun 13th, 2021 06:55 am
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Jim Kovar
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Louis Luu wrote:


Which fork should I use?   :wondering:   :shock:   :P


Last edited on Sun Jun 13th, 2021 06:58 am by Jim Kovar

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 Posted: Sun Jun 13th, 2021 07:39 am
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Jim Kovar
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Jim Kovar wrote: Which fork should I use?   :wondering:   :shock:   :P 




Ain't never had no 12 course meal...

Most All of the "fancy" meals that

I've ever had,...   the utensil in the
bag was always spork.*   :? 











*  Individually wrapped for your protection!   :D

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 Posted: Sun Jun 13th, 2021 07:59 am
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Jim Kovar
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Kidding aside, Louis, your craftsmanship

is absolutely amazing.


My abilities pale in comparison.

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 Posted: Sun Jun 13th, 2021 11:26 am
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David Kilnapp
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Very impressive work Louis!!

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 Posted: Sun Jun 13th, 2021 01:00 pm
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Louis Luu
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Me neither...I only use the fine plastic plate.  That is a plastic plate...don't dare use the fine stuff...my life would come to an immediate end by the boss.  Having fried chicken tonight follow by home brew vintage grape juice (age for a whole month)...rather have that than a fancy 12 course meal.

Jim Kovar wrote: Jim Kovar wrote: Which fork should I use?   :wondering:   :shock:   :P 




Ain't never had no 12 course meal...

Most All of the "fancy" meals that

I've ever had,...   the utensil in the
bag was always spork.*   :? 











*  Individually wrapped for your protection!   :D

Last edited on Sun Jun 13th, 2021 01:01 pm by Louis Luu

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