Aluminum House Sign. Lost Foam Casting
by DuralM in Workshop > Molds & Casting
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Aluminum House Sign. Lost Foam Casting
My street was renamed, so I've decided to cast an aluminum house sign. The easiest casting technology for me is lost foam casting and that's what I like the most.
Making Foam Sign and the Mold
![Aluminum house sign. Lost foam casting.avi_snapshot_00.07_[2017.04.12_09.42.09].jpg](/proxy/?url=https://content.instructables.com/F82/MPR2/J1CEUNH5/F82MPR2J1CEUNH5.jpg&filename=Aluminum house sign. Lost foam casting.avi_snapshot_00.07_[2017.04.12_09.42.09].jpg)
![Aluminum house sign. Lost foam casting.avi_snapshot_00.20_[2017.04.12_09.42.44].jpg](/proxy/?url=https://content.instructables.com/FO1/TJW5/J1CEUNH7/FO1TJW5J1CEUNH7.jpg&filename=Aluminum house sign. Lost foam casting.avi_snapshot_00.20_[2017.04.12_09.42.44].jpg)
I've made a foam plastic house sign and decided to use my huge flask for this casting.
Melting Aluminum
![Aluminum house sign. Lost foam casting.avi_snapshot_01.48_[2017.04.12_09.48.12].jpg](/proxy/?url=https://content.instructables.com/FIN/G7AI/J1CEUNHA/FING7AIJ1CEUNHA.jpg&filename=Aluminum house sign. Lost foam casting.avi_snapshot_01.48_[2017.04.12_09.48.12].jpg)
![Aluminum house sign. Lost foam casting.avi_snapshot_02.15_[2017.04.12_09.48.53].jpg](/proxy/?url=https://content.instructables.com/FWF/6VOI/J1CEUNHI/FWF6VOIJ1CEUNHI.jpg&filename=Aluminum house sign. Lost foam casting.avi_snapshot_02.15_[2017.04.12_09.48.53].jpg)
![Aluminum house sign. Lost foam casting.avi_snapshot_02.44_[2017.04.12_09.49.33].jpg](/proxy/?url=https://content.instructables.com/F5Z/6PGJ/J1CEUMGX/F5Z6PGJJ1CEUMGX.jpg&filename=Aluminum house sign. Lost foam casting.avi_snapshot_02.44_[2017.04.12_09.49.33].jpg)
![Aluminum house sign. Lost foam casting.avi_snapshot_02.36_[2017.04.12_09.49.18].jpg](/proxy/?url=https://content.instructables.com/FRI/8502/J1CEUNHW/FRI8502J1CEUNHW.jpg&filename=Aluminum house sign. Lost foam casting.avi_snapshot_02.36_[2017.04.12_09.49.18].jpg)
Melting aluminum and pouring it into the mold.
Opening the Mold
![Aluminum house sign. Lost foam casting.avi_snapshot_03.03_[2017.04.12_09.49.59].jpg](/proxy/?url=https://content.instructables.com/FE1/WTB2/J1CEUMQ1/FE1WTB2J1CEUMQ1.jpg&filename=Aluminum house sign. Lost foam casting.avi_snapshot_03.03_[2017.04.12_09.49.59].jpg)
![Aluminum house sign. Lost foam casting.avi_snapshot_03.12_[2017.04.12_09.50.13].jpg](/proxy/?url=https://content.instructables.com/FIV/17VS/J1CEUMQ4/FIV17VSJ1CEUMQ4.jpg&filename=Aluminum house sign. Lost foam casting.avi_snapshot_03.12_[2017.04.12_09.50.13].jpg)
The house sign looks nice but I have to make some grinding and sanding work.
The Result
![Aluminum house sign. Lost foam casting.avi_snapshot_03.39_[2017.04.12_09.50.44].jpg](/proxy/?url=https://content.instructables.com/F67/CL3B/J1CEUMQ6/F67CL3BJ1CEUMQ6.jpg&filename=Aluminum house sign. Lost foam casting.avi_snapshot_03.39_[2017.04.12_09.50.44].jpg)
![Aluminum house sign. Lost foam casting.avi_snapshot_03.55_[2017.04.12_09.51.04].jpg](/proxy/?url=https://content.instructables.com/FDG/GN8N/J1CEUN81/FDGGN8NJ1CEUN81.jpg&filename=Aluminum house sign. Lost foam casting.avi_snapshot_03.55_[2017.04.12_09.51.04].jpg)
![Aluminum house sign. Lost foam casting.avi_snapshot_04.01_[2017.04.12_09.51.13].jpg](/proxy/?url=https://content.instructables.com/FKB/3C06/J1CEUNH1/FKB3C06J1CEUNH1.jpg&filename=Aluminum house sign. Lost foam casting.avi_snapshot_04.01_[2017.04.12_09.51.13].jpg)
I put this house sign on the garage wall and really like how it looks.