To celebrate the million subscribers milestone we achieved last week I decided to make once again the project that has been the most successful on my channel:
The only aluminum cast handle hatchet!
This time I went for a pretty different approach compared to lost foam. By reproducing a 3d model of the hatchet head starting from two reference pictures, I made a split pattern that can be used to make a two part mold.
This casting method has many advantages compared to lost foam: it's quicker to make (no need to make the foam pattern everytime and avoids plaster curing time) and can be used over and over without a problem.
For these reasons I decided to challenge myself by making four of the same aluminum handle hatchet. Once the process is dialed in the casting results are very repeatable so I had very minor differences between the four completed hatchets and, to me, that's the best success!
Of course I don't really need four more axes with alumunum handle in my life, so I will keep only one. (The number 3 since I stamped the nuber backwards)

And here is what I want to do with the remeaning three:
- One will be given away to one lucky subsriber, world wide, free shipping. Sign up here:
https://blackbeardproject.page.link/gaw
- One will be given away on my Patreon to show my appreciation to those that really help to keep these videos coming (winner already picked).
- One will go up for auction to hopefully recover cost of materials and shipping for this project. Here:
https://blackbeardproject.page.link/ebay

This is the only batch I will ever make so be sure to join the giveaway!
And if you are wondering the hatchet with aluminum hangle weights 1.2 kg (2.6 lb) while with the wooden handle it's about 0.83 kg (1.8 lb).


Index of operation and materials:

0:41 Grinding paint off and smoothing with flap disk on angle grinder
1:04 Hand sanding to uniform the scratch pattern. Up to 220 grit
1:31 Design head and pattern 3d model in Fusion 360
2:44 3d printing in pla with CR-10s
3:00 Assemble the pattern with ca glue, pins are printed at 97% to cout for press fit allowance
3:37 Baby powder used as mold release
3:41 Petrobond sand (specific oil bonded sand made for metal casting)
6:06 Cutting infeed and outfeed with a tubing
6:37 Risers to increase static pressure inside the mold
6:51 Melting aluminum in coal foundry
7:06 Degassing with sodium carbonate
7:18 Removing impurities with a specific aluminum flux
8:20 Metal cutting bandsaw
8:55 Refining the shape with rasp and file
9:20 Steel chisel to easily clean flashing around the head
9:31 Orbital sander from 40 to 400 grit
9:50 Hand sanding up to 1200 grit with WD40 as lubrificant
10:09 Polishing on cotton wheel with fine polishing compound
10:29 Cleaning up the edge on 2x72 belt grinder with fine belt


Thanks a lot for watching, I hope you liked the video!
Suggestions and comments are welcome.
Leave a like and share to anyone who might be interested!


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