Casting Custom Aluminum Drawer Handles

In this video, I am making some custom cast aluminum drawer pulls I designed for an up coming project. I will use Renshape 460 for the pattern and Petrobond for the sand cast. Stay tuned at the end for a description of my process for the Petrobond after the cast!
Related Videos:
Design Rhyme | Mobile Welding Table | VÄLDBENSH
• Design Rhyme | Mobile ...
IKEA Hack | Mobile Workbench | VÖRKBENSH
• IKEA Hack | Mobile Wor...
Happy Boy Theme by Kevin MacLeod is licensed under a Creative Commons Attribution license (creativecommons.org/licenses/...)
Source: incompetech.com/music/royalty-...
Artist: incompetech.com/

[@XCyclonusX]

That is without a doubt the most perfect casting I've seen on KZbin. Excellent craftsmanship. Great job.

[@CoolKoon]

Actually plaster castings have an even better surface finish. They're a bit more uncomfortable to work with though.....

[@klixtrio7760]

Very hard to make stuff with molds that you have to take out. I would only use plaster if I used wax and melted it out, otherwise trying to split the plaster in two halfs would be awful

[@CoolKoon]

+KlixTrio It depends on the shape of the item, but you're right. I prefer it over sand mostly because of the MUCH better surface finish and the fact that I have a method for making easy copies of the original that's cheaper than using wax (which is quite expensive in fact).

[@75thibaut]

+CoolKoon Could you share your method with us then ? It could be really helpful !

[@klixtrio7760]

Search up green sand casting. It's not the best sand method, but its cheap and works pretty damn well.

[@JerryRigEverything]

Awesome watching you work! Thanks for posting.

[@RishabhPhawa]

Hey Zack, good to see you here ! 😄

[@mrcaboosevg6089]

Bloody hell, that's the best home-brew casting that I've seen on youtube

[@TheGunCollective]

This is one of the more well produced casting videos I've seen. Thanks Brian!

[@user-qi7mt7ov8z]

Какой вы используете песок?

[@n8guy]

Unbelievably cool. Wow. And the casting quality was just off the charts. Well done!

[@owenjackson7207]

Your furnace oozes with profound efficiency and a hint of "Man-Cave." I love the design of your cast, and as I begin the journey of a Blacksmith, I will be using one of your models in my first set. All of your videos are enthralling and informative; Thank you.

[@AshleyWragg]

I've just binge watched so many of your casting videos! I love your attention to detail and quality of your work. Thanks

[@oceantrolls7332]

Your attention to detail and level of skill is phenomenal. Thank you Brian for sharing it with us.

[@carlospitcher4335]

The cast quality is impressive. Bravo!

[@Grunblau]

+Carlos Pitcher Thanks! Like I said, it was better than I expected!

[@DanelonNicolas]

awesome!! unbelievable quality!! ^^

[@Grunblau]

+Nicolas Danelon Thanks!

[@NullBlox]

This whole process looks rewarding through out. The more I watch the happier I become for the results you are getting. You have got a talent for this thats for sure.

[@funksterdotorg]

Cracking surface finish as-cast! Total work of art once you're done with the sanding.

[@brooksnelson7870]

Awesome as usual.

[@Grunblau]

+Brooks Nelson Thanks!

[@brooksnelson7870]

Did you happen to read my email in regards to the MDF machine?

[@williamhayden7711]

I love how you take projects from start to finish... most of the time! Still waiting to see how that domino box and domino's turn out! ;) Edit: Oh and I loved the extra info at the end. That question about the sand being reusable was burning a hole in my head every time I watched your video's. I can't imagine this particular sand is inexpensive by comparison. On the matter of mixing have you seen MyFordBoy's sand reconditioning process? Thank you.

[@nycsheki]

I'm blown away by the quality of all the projects you do. I have always prided myself on being detail oriented but watching you makes me feel like I definitely need to step up my game. Even your videos are edited so well that I don't find the need to scrub through. Thank you for the inspiration!

[@MrCrankyface]

Such a beautiful cast, didn't know it was possible to make them that smooth directly from casting. Great job!

[@nicholasrambaran6307]

what crucible holder do you use

[@ThermalCube]

Skookum as frig!

[@Grunblau]

+makethingz Thanks bro! Keep your stick on the ice :)

[@adir1965]

this is probably one of the best Aluminum casting videos I have seen. well done.

[@WereAllThatBored]

I worked with Renshape at my old job. Once you use it, its hard to go back. Watched this for the casting. Very inspirational.

[@fokinlordsamaels]

honestly, i would like to know reason of some dislikes here !

[@richardkeith1168]

you are the reason

[@Kamal_AL-Hinai]

Dis-i-like

[@johnalexander2349]

He makes the rest of us look like lazy bums who'd rather watch youtube than get off our fat arses and actually do something productive?

[@alexafa316]

@@johnalexander2349 that's all you man. I watch these video to learn and they're very interesting.

[@NikA-ej8le]

Ummm no one has pointed out that he has a CNC machine. So why waste time making a mold, casting and finishing. When he could easily have just cast a block on Ali and set the CNC to cut it. Would he perfect in every way then. Also all waste can be melted into a new block of Ali for next project. Seems like a massive waste of time. Looks nice though, but CNC products are better

[@Grunblau]

+Nik A False. Actually it has been mentioned a few times! CNC part would actually require more finishing after a much longer machine time because it is easier to sand Renshape than Aluminum. If it took 2 hours to machine the pattern, it might take 10 hours to machine the aluminum. CNC chips can be melted down, but the alloy you would use for machining isn't good for casting. I made 5 sets of these so far so there is a huge advantage for multiples. 2 hours to machine and finish pattern and one hour to ram up and cast (total of 7 hours for 5 copies) vs 10 hours per CNC part (total of 50 hours of machine time for 5 copies). CNC result would likely be less smooth unless step over was set really small, drastically increasing machine time.. I suppose it would require less physical labor, but CNC isn't always better!

[@zagmongor]

Right on the money. When producing a large number of parts you would save more time and money when casting versus machining. If you want to factor in the cost of machining versus casting in a manufacturing environment you save way more money when casting. Not to mention the cost of bits for cutting aluminum which would need to be replaced as they dull. Also you waste a lot less aluminum when casting since your sprus and risers etc can be remelted down for the next batch run, whereas aluminum chips off the cnc need to be properly recycled by a plant and wouldn't be able to be reused especially by a DIY home hobbyist. Trust me I have tried melting down chips from a cnc, it all just turns to slag.

[@AcornFox]

If this was true, everything at harbor freight would be CNC machined, and not cast. Derp.

[@philipmacduffie7612]

In a prior career I ran a cnc shop and contracted programming to several. If that part were machined from bar stock you could not fixture it with 4 wood screws. You cant just "drop a cast ingot" on the table of anything and expect it to stay there. If you had any appreciable metal removal rate the gantry style router used here would not be rigid enough to make any money. To not post finish it your step over would be so small you would never make money. Casting this part is the right choice. If you were talking thousands of pieces than sand would not the the most economical. Even if you were to machine it after casting getting it near net would be the best production cost. Though a machined after cast 3d shape would likely require additional steps to ensure porosity cannot occur.

[@jackjax532]

You are so fortunate to have that kind of skill--just love the foundry part of it.

[@lancemumford3106]

I watched this a while back. Had to watch it again. Your expertise is inspiring, I have a few projects that I want to try. Thanks !

[@ShaoLyn8]

you sir are one hell of a craftsman.. its good to see those skills are still alive and well..

[@Emancarrillo]

Love the level of design and modeling that goes into all your projects.

[@jeffy911]

Brian, you do amazing work, especially your attention to detail. LOVE watching your videos. The modern organic shapes you come up with is my style! Please keep them coming.

[@Grunblau]

+Jeffrey I Will do!

[@NickElliottuk]

Fabulous craftsmanship and attention to detail!

[@Apesmedia]

I like how well you have made the whole casting process. Pleasant to watch.

[@Grunblau]

+Ape's metalshop Thanks! Before I was doing a separate video for the pattern when I cast something. Very few people watch the first parts although that is where all the work is!

[@DilipMuralidaran]

Love the finish to the metal. Simple and Elegant.

[@theodoretsinarakis7080]

The nicest furniture handle I ve ever seen... Such display of craftmanship and talent make us other makers feel humble. Really impressed by all of your videos I 've watched so far... Congrats!

[@BrandonLund]

Excellent craftsmanship! Well done!

[@TheRoulette77]

great video production quality... my fav transition is when you're testing the drawers and sliding them, and the finished cabinet appears ! I really like your spru method with the funnel and thin sink plumbing riser what a perfect funnel shape result. The solid craftsmanship of the beer ked forge shows your years of honing your skills. hat tipped

[@peregudovoleg]

Your videos are very enjoyable to watch. I'm sure many people are learning a lot from them. Please keep posting.

[@hey_there]

Wow! Those came out great. Process was really fun to watch.

[@MalikSucksAss]

Those handles and that cabinet design are sick.

[@adamengland6609]

Absolutely stunning. What a great demonstration of different skills brilliantly executed.

[@SeanHodgins]

Awesome design, turned out really nice. You answered question I had at the end the end of the video. Thanks for the extra info.

[@mdoering]

Great explanation on the process and amazing results. Five years later and this is still the best quality casting I've seen on youtube. I used green sand/petrobond like this to make a sterling silver pendant for my wife back around 2009-ish. KZbin was not yet the incredible resource it is today. I modeled the piece by hand in wax and then followed this same process with amazing results. The kicker is, it was a key with a heart shaped top, and the key is a fully functional duplicate for a master brand lock she uses for a memory box, except entirely sterling silver now.

[@Grunblau]

Awesome story, thank you for sharing this!

[@TheScalemodelingChannel]

Love the design!

[@kevinwillis6707]

i remember watching you build that cnc years ago, good to see its still working away, love the casting.

[@Grunblau]

Thanks! Been a crazy journey!

[@vinodmehra188]

The casting was so smooth! Amazing! 😲

[@christopherneelyakagoattmo6078]

I can say that you are on par with the few Masters that I have had the pleasure of working near. A rarefied air is forming around your work. I do not particularly care for that particular combination of brushed aluminum, with light hardwood, normally. It works a bit for me here. There is no accounting for taste, and mine does bot run that way; but you are drawing me in... such is your refinement of form, fit, function, and aesthetic. Having said all that, cast those in a brass, bronze, copper, or a darker pewter; and I am sold as a neo-classic all day. Bravo.

[@scobob]

Yeah, some people are brass and oak and then there are those with taste. Seriously, brushed copper may look pretty cool with a birch ply

[@leester9487]

That Renshape makes beautiful uniform chips, great for machining. I heart birch plywood.

[@tracythemutt817]

those drawer handles looked beautiful!

[@daretoreef]

I have to say, you do an amazing job in your videos. I love how detailed they are even the part at the end where you show what to do with the sand. I would love to see more videos!

[@JDeWittDIY]

Wow, everything about this is absolutely beautiful!

[@dagmarl8061]

OMG !! Das ist das genialste was ich auf KZbin gesehen habe und dazu noch so schöne Maschinen ! Thank you very much for your Video. Greetings from Germany

[@GregsGarage]

It looks like that was a TON of work to get those pulls made... TOTALLY worth it though. They look amazing. Thanks for bringing us along for the journey.

[@Grunblau]

+Greg's Garage Thanks for the comment! Not that hard at all... The biggest PITA is ramming up the sand. I have made 5 sets of them now!

[@silasmarner7586]

The finish work is most excellent!

[@WastedProps]

You are a true credit to your work mate. amazing as always! I'm halfway through building a keg foundry much like yours and have been using your videos for pre-research for being able to extend what I'm able to build for my prop business.

[@yuebao8911]

It's really a piece of art! I hope next year when I decorate my house, can do the same work like yours.

[@Imwright720]

Stunning. Beautiful design

[@mcseforsale]

Those are beautiful. And a beautiful piece, as well. I'm building more and more plywood furniture. I love the way it looks. Thanks for the vid.

[@Grunblau]

+Ajey Thanks for the comment! I have a huge plywood furniture project coming up...

[@drive67ray]

A craftsman at work,a joy to watch

[@M3rVsT4H]

What a great vid, one of the cleanest molds I've seen, and the results are suitably impressive.

[@Grunblau]

+Merv Thanks!

[@BungieFrog]

Very nice work. Enjoyed the video and the passion you have for a well refined finished product. Inspiring! Thanks for sharing.

[@billmoss401]

Wow!!! Impressive!!!It reminds me of working with Aircraft parts when I worked at Boeing Company years ago!!! Beautiful work.I like watching you Leather Working videos also.

[@maidique]

Wow, Brian. Your work is spectacular! I have a company that "makes things", and we strive for the level of work you seem to consistently put forth. Bravo.

[@nateallen2947]

Excellent video. I loved the design of the handle.

[@catherinehamon1001]

Video well done. I'll be using it for my materials and processing class to illustrate the sand casting technique. Your drawer pulls are very nice as well!

[@GetHandsDirty]

Excellent video and showcase of the process!

[@Grunblau]

+Get Hands Dirty Thanks!

[@hotmelts3076]

boy.. I wanted to cast aluminum but I think I just watched the holy grail and will never compare.. that's amazing and beautiful very nice work! super jelous

[@Grunblau]

+Steve Simons Thanks!

[@LuKifUA]

Good job. Unbelievable quality!

[@4Ksa4Ever]

beautiful craftsmanship as always Brian and plz keep the videos coming

[@MakerTable]

Wow! Incredible craftsmanship to master all these different skills, keep up the awesome vids!

[@terrafree]

Wow!! Really nice job Brian! Thanks for sharing

[@CSSIandAssociate]

Pretty slick and one of a kind. Nice!

[@sk3tchimdg3t33]

Your skill is truly awe inspiring

[@AlejandroNietoan]

Excelent work! Those drawer pulls are beautiful

[@brycec42]

Your channel is always one that I look forward to new content from. Awesome video.

[@wizardjo]

This work is absolutely beatiful. Thanks for sharing.

[@jedizero2]

Absolutely beautiful and inspiring! Thank you for sharing.

[@whazzzzup1985]

This next level craftsmanship! Amazing

[@NathanNostaw]

Great design and fantastic finished parts. Thanks for the video.

[@koenjanssen81]

Nice video!! I really like how you explain everything, and the finished product is more than perfect

[@mouradpacha2670]

GREAT AND INTERESTING VIDEO, YOU ARE A REAL PRO, thank you for sharing your knowledge

[@wintersnot]

Gorgeous pulls! Nice job!

[@lancemumford3106]

I really enjoyed your video, you did a great job and gave me some ideas to try myself. Thanks !

[@jo2lovid]

Beautiful artisan work. You have created some lovely, organic, flowing curves in those handles.

[@Grunblau]

+Joanne Lowery Thank you!

[@wurmbunt]

I am impressed! Well done

[@jamesmcmillen4828]

VERY nice cast! Very well done.

[@yashjoshi]

The Time lapse part of the video along with the audio is sooo Satisfying to watch..!

[@NafanyaZX]

Very impressive. Thanks for allowing us to learn from you.

[@DaveHernandez_davido]

That turned out so awesome...great design!!!

[@GogogoFolowMe]

The surface quality is awesome for a casting !

[@Grunblau]

+GogogoFollowMe Thanks! I was super happy when I shook it out!

[@americandowninbrazil]

Great video man and great job on the pulls! I loved most how you added all those cool sound effects and kept it really moving.

[@pethoviejo]

Gorgeous. Nice work.

[@rowanmcintyre]

Beautiful work!

[@Cactusworkshopchannel]

OH my god this looks fantastic!!!

[@unogazzy84]

Your videos are very well made and those handles are very beautiful.

[@clarkso65]

Amazing! Mark of a True artist.

[@JV-pu8kx]

Always wise to think about the future when making molds, models, jigs, etc. You never know when they can prove useful, again.

[@maxrosenblum4187]

Gorgeous work, Brian!

[@Grunblau]

Thanks!

[@pfrieden1]

Those, sir, are absolutely beautiful!

[@Grunblau]

+Paul Frieden Thank you, sir.

[@thebossrickross5695]

Amazing job. They look slick

[@timguba8887]

Outstanding work! Very nice video. Well done!

[@CheetoTheCat]

Very impressive craftsmanship! Your design is beautiful as well.

[@Grunblau]

+Don Z Thank you!

[@baccus61]

Beautiful job Brian and very well presented. Thanks.

[@sierraecho884]

What a beautiful cast