Casting an Aluminum Bronze Replica "Bronze Age" Spear Head in a Vertical Sand Flask

Huzzah! success! This just goes to show, if you take a 3D printed scan of an ancient bronze spear head, cast it in the wrong bronze alloy (aluminum bronze vs. tin bronze), and pour into the wrong casting medium (petrobond sand vs. stone molds), you're gonna have a bad day. Also, anything is possible. With enough ingenuity and sheer stubbornness, you can make stuff despite problems.
This is the second attempt at sand casting this spear head. The first attempt is at • Casting an Aluminum Br...
In that video, I talk much more about bronze age casting and this particular spear point. If you were expecting rambling about the spear itself and about "bronze age" and what that means, watch that video. This video is the successful bronze casting.
If you want to hear much more rambling about aluminum bronze as a specific alloy, watch this: • The Bronze Alloy as To...
In that video, i make the aluminum bronze from scrap copper and extruded aluminum
Olfoundryman's channel: / @olfoundryman8418
Here's the 3D print i used: www.myminifact...
Mailing Address:
1818 Milton Ave STE 100 #1973
Janesville, WI 53545-9998
We have a community Discord server. To join, send me an email at [e-mail], or click here: / discord
Follow me on twitter at / vloggarage
Instagram: / pauls.garage
Patreon: / paulsgarage
Music: "Quirky Dog" by Kevin MacLeod. incompetech.com/
#metalcasting #knifemaking #archaeology #bronze

[@netx421]

This was the classiest pour I've ever seen.

[@Lccastaldo]

You do NOT need to have sprue envy! MAKE some!! Love your videos!

[@stamasd8500]

You should hammer on the edges before sharpening to work-harden them. Congrats, looks good. You should make an oversized arrow is my vote. For a ballista. :)

[@PaulsGarage]

Haha huge arrow would sweet looking!

[@dwwolf4636]

Wouldnt CuAl9 be near 100 HV as cast ? As opposed to the 70-80 of CuSn10.

[@djericanthony]

I’m planning on doing something similar but will go the lost foam route and then get to grinding/whacking it into shape. I will do a video as well. I’m gonna try a socketed one with the socket being cast along with the blade.

[@heraclestheodoros2518]

I really wish to try this out. Making a bronze spear or bronze sword sounds really cool 😎. Good job 👍🏻.

[@360xdnox5]

me too

[@NathanielOutdoorAdventures]

I am really loving your videos. So very cool. I will not comment on every one but slowly working my way through them

[@bombswabs3041]

@ 1:15 Thankyou for saying to pre heat the sand. I haven't even started this cool hobby and of the 20 videos I have seen. Not one mention of pre heating the sand. I cant imagine why that wouldn't work. Caveat. I commented this before watching the whole video. So I guess I will see if this is effective.

[@Robc509]

Nice job! Turned out great!

[@christophermanfredo2241]

Patreon and huge fan! Glad your back is feeling better!

[@PaulsGarage]

Thank you good sir! I may have tweaked the back a little bit this afternoon, i think a chiropractor is in my future

[@AlumiTube]

I love it paul great work 😁

[@PaulsGarage]

Thanks!

[@p3asant]

Would it be acceptable to make the patten with a thickened edge then grind and sharpen the casting after pouring.

[@TheSkaireKrowe]

Very nice, Paul. Congrats on your success.

[@PaulsGarage]

Thanks! Im happy with the casting

[@christopherj5780]

What if i used tin bronze and aluminum and additional copper? What would that look like?

[@daltonmast9982]

I highly suggest using an air compressor to lightly blow the loose sand out and also blow the pour hole out really good and you'll almost never have any problems with getting sand in your castings and don't be afraid of getting a little break off especially on something like this because the grinder will clean it up real quick

[@PaulsGarage]

i've been meaning to make one of those set ups. I have a compressor i just haven't had the time to set it up

[@dizzolve]

is baby powder just as good as parting compound? ..... thx

[@qtpie2630]

I don't quite understand how the socket is made like how the core is kept from moving but still have enough space for the metal to slide please help

[@stevearehart313]

What was the final ratio of copper and aluminum?

[@panikrev175]

Cheers, you did a fine job on that casting. Keep up the great videos.

[@PaulsGarage]

Thanks! Im happy this turned out

[@davemo04]

Looking good! I like the unboxing knife idea. How about a hand carved wood handle?

[@PaulsGarage]

That would be really cool. I have some cool wood laying around

[@johnmccanntruth]

Always enjoy the videos!

[@PaulsGarage]

Thanks!

[@MrPipvampire]

I really like your vids. How about doing a lost wax cast mould? That would be VERY educational. My 10kg foundry is in the post on it's way to my house and I want to cast small intricate sculptures in the future. So, what do you think? Up for the challenge?

[@PaulsGarage]

I would love to do some of that. Its on my list, I just haven't gotten to it yet

[@badsantaclaus4522]

Spear head looks great!

[@PaulsGarage]

Thanks!

[@ColtFlenn]

Question: When you use the muffin tin to make the pucks, how do you prevent copper/bronze from braising/sticking to the steel of the steel muffin tin? I have had this problem with hotter metals? Aluminum pops out cleanly, but copper/brass/bronze tends to stick/braise and ruins the "ingot" mold.

[@chrisweber6443]

Awesome job Paul!! Inspiring me more and more man.

[@PaulsGarage]

Thanks! Im happy that this turned out. Aluminum bronze is awesome stuff

[@AugustGunsZERO]

Paul I've noticed a severe lack of safety equipment. Do you know those paper dust masks? You should get them they're perfect for covering your coffee cups and mugs

[@PaulsGarage]

Thats a great idea!! I wear a respirator but my coffee gets all crummy

[@AugustGunsZERO]

Yeah the paper ones are terrible for personal use, but they work great for coffee cups the nose clip fits over any handle.

[@emiliogreenwood8190]

Looks like it turned out pretty good anyway I was afraid to sand will collapse when you pour the metal

[@PaulsGarage]

I poured pretty hot, much hotter and it might have collapsed

[@djericanthony]

I’m :55 seconds in and stopping to just say. WHY cast thin? Wouldn’t you think that the solution, that even the people of the time did, was cast slightly thicker and pound the rest of the shape thin? Also, the artifacts that we have now were not as thin originally due to the decomposition. That’s my guess now, I could be completely wrong. Also, I think they used heated soapstone as well

[@PaulsGarage]

Yeah heated stone is definitely what they used. The bronze artifacts wouldnt have corroded away and gotten thinner but the casting originally would've been thicker around the edges out of the mold and hammered like you said

[@TheHairyBeastie]

Your trowel has served you well. Now it's time for something you made yourself to get the limelight. (leather working sounds good too, perhaps do a video on it?)

[@techdnrp2432]

Great job! You're making me interested in trying alloys sometime. I'm also going through the Gingery book, is how I found your channel.

[@PaulsGarage]

Thanks! Ill get to the gingery lathe as soon as i get a big crucible. I made the lathe bed a little different from the book and it will require a LOT more metal. Gonna use a different alloy for that, too.

[@techdnrp2432]

Looking forward to it!

[@balkamp8888]

Hell yeah! Nice casting!

[@PaulsGarage]

Thanks!

[@jamesanderson7698]

I didn't even need to watch to know you succeeded. Wisconsin can blame your successful casting for the 6 more weeks of winter... (this comment will probably confuse those that didn't read my comment on the 1st attempt video) Congratulations on the spear-nife.

[@PaulsGarage]

Yeah the freezing cold weather and snow fall certainly gave it away. They even salted the roads again :(

[@danharold3087]

Nice work Paul.

[@PaulsGarage]

Thanks dan!

[@rodneysrepurposingrecyclin3821]

I really enjoy your videos. Your personality is s good selling point. The spear/pig sticker is cool.

[@PaulsGarage]

Thanks! Everyone always said “well, at least he had a good personality”

[@rodneysrepurposingrecyclin3821]

Paul's Garage I enjoy the lighter side of things. If ya can't have fun, you're doing it wrong.

[@heraclestheodoros2518]

I really enjoyed the video where you made that bronze spear. Good job 👏. Now How do you put that spear head on the wooden shaft if it does not have a hole for the top of the wooden shaft?

[@tonymasont8636]

It should be hollow at end to allow wood to be inserted and held in by two cast lugs with twine on head pulled back and wrapped to secure onto wood also would not be shiny for hunting

[@Raytheguardian]

Great job 👍

[@PaulsGarage]

Thanks!

[@timrauscher3965]

Nice job. I think it came out very well. Put an extra long handle on it.

[@PaulsGarage]

Thanks!

[@MaturePatriot]

Have watched 'myfordboy' do castings. He and 'oldfoundryman' are the best, in my opinion. - It's a SPEAR POINT, so I would put it on a spear. lol - GOOD JOB!!

[@PaulsGarage]

Yeah myfordboy is another good one for sure. Also luckygen1001, chirpys tinkerings, lots of good ones

[@adcaptandumvulgus4252]

I vote spear you need the extra toughness of aluminum bronze to withstand the forces exerted by using a big lever so make sure you use a good straight grain somewhat flexible Woodstock Osage orange/ bodark maybe (if you can get it)

[@PaulsGarage]

I can get osage orange at woodcraft, that would be fun.

[@treym8561]

Would you be able to make a lead hammer????

[@PaulsGarage]

Probably, lead is really low melting point. I dont have any lead, though

[@duanebarrett2409]

Also, lead is very soft. It wouldn't make a great hammer. Oh and poisonous, lead is poisonous as well. You can mix it with Antimony to make it harder, but that also makes it brittle. Oh and Antimony is even more poisonous than lead.

[@dallaswoiken7533]

Great job on the spear 2.0 .I think u should cut those screws in your mold. lol been there done that and hurts like hell

[@PaulsGarage]

Yeah good call, those buggers are sharp///

[@dallaswoiken7533]

Paul's Garage yep I was building planter box's for my Girl Friends mom and wasn't Paying attention and got myself .lucky no stiches after that soon as I had the screws where i wanted them I cut them right away that way her mom wouldn't get hurt wile she was planting .

[@texastaterbug5395]

Great video! When you're trying to fix a failed process, it's important to change as many variables as possible every time. ;-)

[@billymartinozarkmountainfo225]

Would u melt down some brass? If I send u some bub? Wanting to make gards and bolsters out of then. Would u be willing to do something like that? Thanks

[@PaulsGarage]

Hello! Im trying to avoid melting brass actually, the zinc fumes are baaaad stuff and i dont have a crucible for melting brass. Sorry about that.

[@billymartinozarkmountainfo225]

K I got a coal Forge. I will see what I can do. I got something I can use as a crusable. So let's see.

[@terryg4179]

Excellent vid.

[@joegomes4885]

Looks great

[@CirroJeremy]

Did you get some April snow?

[@PaulsGarage]

I did indeed

[@donniebrown2896]

Oversized letter opener, keep it on your desk and when someone irritates you just calmly pick it up, scatch your beard with it, and ask them to repeat what they said. Good job think the venting and preheating you mold helped a lot.

[@PaulsGarage]

Haha letter opening and intimidation

[@SkyForgeVideos]

Why aluminum bronze? Is it stronger?

[@PaulsGarage]

Yeah aluminum bronze is stronger than tin bronze, holds an edge better, work hardens more. It's used for tools and bearings and stuff for that reason

[@SkyForgeVideos]

Thanks so much!

[@nowayjerk8064]

whats under the thermometer?

[@PaulsGarage]

Bunch if springs from an ild box spring dealy

[@nowayjerk8064]

your face is a dealy errrrrrrrrrrrr ummmmmm sorry slipped , thank you

[@scottgarvinjr8262]

Welcome back, Paul. How's your back feeling?

[@PaulsGarage]

Pretty good actually, thanks!

[@scottgarvinjr8262]

Paul's Garage Great, you're welcome

[@emiliogreenwood8190]

You could have clams some boards to the side of your flask

[@GTJay]

Sardines come in short, flat-ish cans. (At least, down here in SA TX)

[@PaulsGarage]

Makes sense. I still dont like them ;)

[@oliverludwig6148]

"old foundary man. he is, i assume an old man, who does foundary stuff..." woah, my mind is blown!

[@massimoserra4787]

Yeah Paul, looks awesome :D

[@PaulsGarage]

Thanks! Im pretty happy with it

[@ypop417]

Verry nice Paul

[@PaulsGarage]

Thanks!

[@ypop417]

You are Welcome!

[@kevinmencer3782]

"Screwed it up by yawning too big." Been there, done that.

[@marcsenteney3160]

Very nice!

[@PaulsGarage]

Thanks!

[@marcsenteney3160]

Paul's Garage you and your (counterpart ? Swdweeb ?) are very informative with your casting projects and is a great help on my castings

[@louismorgan7102]

no probs

[@nickd5943]

Looks great.

[@PaulsGarage]

Thanks!

[@nickd5943]

Not being a troll or just an A-hole!! Joking with you!!! “ you could make a mail opener thingy, but in about fifteen min. you would lose it!! Lmbo!! Love your vids and your personality. Oh where in Gods green earth did you get that power paint/grinder thingy? What did it set you back? And how much are the replacement roller/ sander/grinder thingys??

[@ronyerke9250]

You don't NEED a sock for parting compound, just a piece of fabric that will hold it until you shake some through. Try an old T-shirt, or bandana with a rubber band or twist tie. There's gotta be other hacks too. I wonder if Sarah has plans for your spear point.🤣 👍

[@PaulsGarage]

I hope she doesnt plan to use it! Otherwise either me or the cat is doomed

[@ronyerke9250]

Do you remember a woman in tbe news a decade or so ago named, Lorena Bobbitt? 🤣

[@darinmbicknell]

How many 'nah ish's' per centimeter?

[@PaulsGarage]

42?

[@ChaosPootato]

Awesome!

[@PaulsGarage]

Thanks!

[@simpleman806]

Looks better than the 1st

[@PaulsGarage]

I agree! Didnt shatter either which is a plus

[@damionbotello7523]

Tell me why i don't watch for the content I watch for the randome stuff he talks about and the on screen text XD

[@tommytigert5993]

Because this dude is hilarious!

[@FranklyWry]

If you have bears or cougars in the neighborhood, make a spear. Their forelegs are pretty short, but I would still make a long handle out of hard wood. Me go crazy when bear ramble into backyard.

[@dfross87]

Did I miss something? Where was the cool noise as you dropped the ingots into the bucket? Don't tell me you cut that bit!?!

[@PaulsGarage]

Yeaaaaaah i cut that bit. Ill leave it in next time ;)

[@Del350K4]

Congratulations - I´d make it into a knife because one tends not to use one´s spear very often, whereas a knife is something you´ll use and engage with.

[@PaulsGarage]

Yeah thats what im thinking. I use a knife all the time, spear never

[@Del350K4]

I only have one spear. I made it for a KZbin video and now it lives in the broom cupboard, where it amuses itself by toppling over whenever I try to put the dustpan away.

[@scififan698]

do you always to mould making in shirt and jacket? lol

[@jgclark45]

2nd times a charm

[@PaulsGarage]

Beats fifth time for sure

[@wafflezoot]

So you are a fan of live fish in a can?

[@PaulsGarage]

If by can you mean fish tank, then sure!

[@sirlancer23]

Make an unboxing spear!

[@danvandertorre9280]

take it too work and wave it around saying I need a promotion and see if it works .lol

[@PaulsGarage]

Haha promotion, get fired, something will happen

[@danvandertorre9280]

or maybe the boss has a gun and already knows your crazy like me and the day ends badly so no its a bad idea ,what ever you do don't hammer harden it will chip off .

[@Joe-dw8sh]

Shiny stabby

[@PaulsGarage]

Not that stabby, it isnt sharp at all. A spoon is sharper

[@oliverwalters9533]

Paul's Garage make the stabbby SHARP

[@fredwilson9656]

I have a WW I spike bayonet I inherited, it is not 'sharp', but put the weight of a soldier and rifle behind it and it will go all the way through a training mannequin like the army used to use. Sharp is for making neat incision, somewhat dull can be super deadly and is a lot easier to maintain.

[@mrgreenswelding2853]

You should put a spear handle on it so you can use it for hunting! 😁

[@PaulsGarage]

The only thing i have to hunt around here are deer and squirrels, im not sure when “deer spearing” season is. Ill have to look that up haha

[@mrgreenswelding2853]

Paul's Garage the spear should be good for squirrel hunting! Lol!!

[@mikecunningham3423]

9:04 Here's an idea just use clamps

[@PaulsGarage]

Didnt have the right size clamps :(

[@mikecunningham3423]

don't take this personal im just being a dick for comical reasons i really enjoy your content keep it up

[@rljzathras]

PMSL - baby grunts - yeah only a parent knows that one :-)

[@PaulsGarage]

And the accompanying red face...

[@scottgarvinjr8262]

I try to save all my petrobond and Paul drinks his.

[@swdweeb]

Sprue envy is nearing an end. :-)

[@PaulsGarage]

Well thats good, envy is such a nasty feeling ;)

[@ukaszanioowski9722]

hmm... aluminum bronze arrow heads?

[@PaulsGarage]

That would be soooo cool

[@dizzolve]

9:30 pignose flask

[@nickhollister9483]

love it

[@PaulsGarage]

Thanks! Me too

[@louismorgan7102]

2nd viewer, love you man

[@PaulsGarage]

Thanks!

[@emiliogreenwood8190]

You could have clamp

[@PaulsGarage]

Unfortunately my clamps are all too big or too small :(

[@corviniago6456]

Definitely don't use Tig welding gloves haha

[@patrikmauritskronholm4684]

mmm liquorice sardins :)

[@jbwelch89]

lol ya know ya wanna make and sell me a dagger blank!!!!

[@PaulsGarage]

Haha if i ever make a permanent mold ill keep that in mind

[@al9094]

Very nice i would make it look like a replicate of a roman reproduction spear and sharpen the snott out of it .then give it to a KZbin viewer with the best idea. Or hang it on the shop wall for all to see.

[@gramursowanfaborden5820]

aluminium bronze... anvil?

[@jeanladoire4141]

Hammer harden it, sharpen it and make a super duper spear out of it ! Then try poking targets with it :)

[@PaulsGarage]

I have an archery target, that might work

[@jeanladoire4141]

Paul's Garage Im practicing the Historical European Martial Arts, the spear is quite simple to use, if you're interested in ancient fights, you could watch on the internet how to thrust and cut with it to have fun ! Try plastic bottles, cloth, pieces of meat maybe ? And try to throw your spear like a huge javelin... That's a lot of fun you'll see

[@Zillustration]

Well done! Looks like you're ready for Philistine invaders!

[@stamasd8500]

Philistine, Parthian and Persian alike. Maybe with some Phoenicians thrown in for good measure.

[@PaulsGarage]

as long as they didnt bring their own spears!

[@macy725]

Hunt boar with it.

[@Kintepro]

117th!

[@madsighntist14]

Leave as is!!!!

[@TheByteknight]

Why dress in business casual for casting work.. :-)

[@039stephen]

First like.

[@PaulsGarage]

Thanks for the like, but i think a dozen people beat you

[@039stephen]

Ye probably. I'm never usually like that haha. Keep up the work love your videos.

[@IronBridge1781]

They let you have a child!?

[@PaulsGarage]

More than one! Isnt that nuts? Im gonna teach them to weld when theyre older, itll be great. First i gotta learn how to do it though..:

[@IronBridge1781]

Paul's Garage That sounds like it’ll be a fun thing to learn together, I’m actually a fully trained and licensed welder myself in MMA, MIG and TIG. Though if I learned any one thing from my time it’s that “a grinder and paint make me the welder I ain’t.” So don’t be too hard on yourself if you mess up. On another note I actually have a foundry myself, capable of melting cast iron no less. You think you’ll ever foray in iron territory? If so I can provide you some info and reference material if need be.

[@preacherjayk]

you might try carrying a pocket knife,, lOL

[@twatrrf306]

FLOUR SIFTER!!!!!

[@PaulsGarage]

Im currently banned from stealing more kitchen equipment :(

[@twatrrf306]

Paul's Garage I will help find a way.....some how

[@mikehewitt1253]

Sorry Paul watched the 1st attempt and now this one .............................. the CONSTANT chatter actually makes me miss anything useful you may be saying you drown out meaningful communication by constantly not shutting up!

[@Jordan-rb28]

Fifth!

[@PaulsGarage]

Can confirm fifth

[@denispopov3553]

study mark queen works along prosecutor united testify train resort violence safe order.