If aluminum casting fails, there is always JB weld as a possible material to use as a casting resin. Its heat resistant and should be at least as strong as the plastic once its cured fully. On Tue, May 14, 2013 at 12:48 AM, William Wilson wrote: > I'm a little late commenting here, but I do backyard foundry work all of > the time. > Your technique should work fine as long as the plaster mold is baked dry. > Toss it > in a 500 degree oven for an hour. Water and molten aluminum don't mix. > You can buy 10 gauge aluminum wire by the foot from most home improvement > stores > and it melts easily with a torch. > > One thing to think about though, that new aluminum gear is going to heat > up and may melt > any plastic gears that it is in contact with. > > > Cris Wilson > Information Resource Consultant > College of Architecture, Arts, and Humanities > Clemson University > 864-656-6081 > > -----Original Message----- > From: piclist-bounces@mit.edu [mailto:piclist-bounces@mit.edu] On Behalf > Of veegee > Sent: Tuesday, May 14, 2013 12:20 AM > To: Microcontroller discussion list - Public. > Subject: Re: [OT] Making a new spur gear > > On 2013-05-13 10:36 PM, Marc Nicholas wrote: > > But prove everyone wrong (safely!) and post before and after pics. :) > > Seems like I have to. I have already done a similar thing some time ago > with cheap solder instead of aluminum for a lower temperature application= .. > The quality of the part was better than the original after some light > polishing work. > > Hasn't anyone here heard of backyard foundries? Flower pot furnaces? > Casting metal is easier than you think. > > -- > http://www.piclist.com/techref/piclist PIC/SX FAQ & list archive > View/change your membership options at > http://mailman.mit.edu/mailman/listinfo/piclist > > -- > http://www.piclist.com/techref/piclist PIC/SX FAQ & list archive > View/change your membership options at > http://mailman.mit.edu/mailman/listinfo/piclist > --=20 Jonathan Hallameyer --=20 http://www.piclist.com/techref/piclist PIC/SX FAQ & list archive View/change your membership options at http://mailman.mit.edu/mailman/listinfo/piclist .