How to Upcycle a Cheap Lava Lamp With a Cast Aluminium Base

[@StuartsShed]

Masterfully done - thoroughly enjoyed this. Also bonus look at the kitty who sneaked into the shed. I am very fond of cats. Well, creatures in general. All the best.

[@Preso58]

Our two cats often do that and I don't notice them until I look back at the video later. Regards, Mark

[@TheAyrCaveShop]

I was holding my breath during the molding and casting. That was a ton of work. Glad to see it was a good outcome. I think Gorge Jetson will approve 👍👍

[@Preso58]

Thanks Dean. One off castings are always a hit and miss affair. It's rare to get a good casting first time round. As it turned out, the failure gave me an opportunity to add a few Jetson inspired features to the finished lamp. Regards, Mark

[@johnmolnar2957]

Love your collection of home made $1,000 lamps

[@outsidescrewball]

Awesome discussion/build/video production….looking forward to the countdown for liftoff 😊

[@Preso58]

Thanks Chuck. The lamp is now finished and it looks great. I think I will buy another cheap lamp as a spare because the bottle part doesn't last forever and I guarantee, if I try to buy one a few years down the track, they will be either different or unavailable. Regards, Mark

[@andrewdolinskiatcarpathian]

Hi Mark. Truly outstanding. A veritable “home casting” masterclass. The upscaled lava lamp will be a triumph. Can’t wait to see the next episode. 👏👏👍😀

[@acmemachining]

Amazing job Mark. Thanks for sharing.

[@lucpet95]

Very nice Prezzo As an armchair expert I did think those legs needed some air vents when watching lol

[@Preso58]

You are absolutely correct and I did consider doing it but, well, I didn't. I think the sun was in my eyes😁 (generic excuse). Regards, Mark

[@myfordboy]

Quite a chalange that one but you pulled it off.. I am thinking adding some risers to the all the legs would have prevented the short pour. Try it on the next one!

[@VladekR]

👍

[@Preso58]

Yes that was quite the oversight on my part. I was so focussed on getting the coping down part done that I overlooked the venting. Still, it actually gave me the opportunity to add some extra bling. Regards, Mark

[@thercbarn5001]

Amazing project!

[@thehobbymachinistnz]

Good start Mark. It never gets old watching you do that sand casting. I really enjoy it, then we get to see the cast item when it has cooled. It was good that you can use the first attempt, I bet it takes quite a bit of time to re do it if you have to. I have not had spinny legs flying around on the metal lath, but I know what you mean by it is a bit scary. In woodturning I have made a few winged bowls and it is a bit the same with wings flying around all over the place. It is very easy to catch the tool on a wing, or worse, have your hand or a finger touch a wing...

[@Preso58]

Thanks Jon. I was so confident when I first opened that mould. It really is a humbling experience when you see a fail like that. However, it has turned out better that the original design. I know what you mean about snatchy, spinny, hard to see parts. Regards, Mark

[@notJW13383]

I have used epoxy for similar AL castings. I use 2% epoxy by weight and then mix with acetone for blending with the sand. Also I have cast car diff covers that have the same hanging cope problem. I added a partial disc and rod fastened down through the cope to support the extra weight. Love your videos!

[@Preso58]

I should try using less epoxy. I generally use between 6 and 8% but I guess that adding the acetone will wet the sand better. I was told after the event that I should have turned the mould upside down so the cope was underneath when separating the first mould. I will try that next time. Regards, Mark

[@joell439]

This is a beautiful and creative project. I sure wish I could be this creative. Thanks Mark for showing us just a fraction of what it takes to create such unique pieces of artwork. 👍😎👍

[@Preso58]

Thanks. It's all fun and games until you open the mould though. As it turned out the fail led to an even better outcome though. Regards, Mark

[@scottloudon14]

Once again, very impressed.

[@dlstanf2]

Fun and interesting video. Thanks for some nostalgia.

[@Preso58]

Lava lamps and fibre optic lamps! You almost never see them much any more. Regards, Mark

[@MattysWorkshop]

Gday Preso, that’s was really interesting to watch, I can understand why you weren’t keen on doing it twice with how much effort went into the first go but you nailed it, great job as always mate, cheers

[@Preso58]

Thanks Matty. It gets old real quick if you have to redo a mould like that. On some jobs I have made a mould three times until I get a good one and then you ruin it in the casting process too. I did watch Clarke Easterling and his work on the Tally-Ho capstan project. He's an expert and even he made the mould at least half a dozen times. Regards, Mark

[@russtuff]

I really appreciate your attention to detail.

[@RogerSchoeni]

That is so cool Mark. Only downside is that feel now I have to search for my old lava lamp and start modifying it.

[@Preso58]

You are lucky to have an older version. The new ones seem to be cheap and nasty. Regards, Mark

[@robertwragg9224]

Top job dude turned that around nicely

[@Radiotexas]

Absolutely remarkable mate! Great minds (or dirty minds) think alike! I was thinking the same thing when the picture of the "leather and latex novelty" store popped up! I well-remember lava lamps. Different time, different attitudes way back then! Will be anxious to watch the liftoff!!!

[@Preso58]

Thanks. I badly wanted to use the word "phallic" but it might have upset someone.😁 Regards, Mark

[@thisnicklldo]

I well remember these first appearing in the UK in the late 60's. My next door neighbour had one, and as a kid I was both fascinated and jealous. Then they became naff. Now it appears they have become retro. The original bottle was the same bottle as was used for a brand of fruit squash/cordial (where you dilute with water, very sweet and sticky) called 'Treetops'. I've just had a look but unsurprisingly the old bottles are no longer around. The one you have is close in shape, but not exact - I'm not sure whether the ones still provided by Mathmos are the same as they used originally, they might have had to switch to their own shapes when the branded juice bottles disappeared, some time in the last 60 years. Tricky casting - I feel like you could have cast or machined 3 legs and a separate base, then joined them, more easily, but where's the fun in that I guess.

[@Preso58]

I did consider making separate fins either by machining from solid stock or by making individual castings but the joints were always going to be tricky and adding fasteners was also complicated. At the end of the day, I wanted to try a casting that required coping down to a 3D parting line. That part was relatively simple but making the cope was not. I was told later on that I should have turned the whole mould upside down to keep the domed part of the cope from obeying gravity and falling off. I will know better next time. I read a bit about the original Mathmos lamps. I half expected Edward Craven Walker to be a long haired hippy but he looked like the most conservative British gentleman ever! Regards, Mark

[@tobhomott]

Good idea for that epoxy core. I think I would have used normal molding sand for the whole thing, but turned the mold upside down to open it. Anyhow, many ways to skin a catt as they say. I can already tell the lamp is going to look amazing. 👍

[@Preso58]

Doh! Why didn't I think of that? A great tip. Gravity can ruin things real quick. Regards, Mark

[@Warped65er]

Great vid., and I too was wondering if venting on the legs would have given you full fill, but I also saw your replies to other commenters.

[@Preso58]

Yes, in hindsight.... Ah well, it actually turned out better but more work of course. Regards, Mark

[@northerntrout6807]

"I dig the fins..." - Frank Zappa. George Jetson would love this.

[@Preso58]

Thanks Dennis. Yes, the Jetsons were something of an inspiration for this project. I had forgotten how cool that Hanna Barbera series was. Regards, Mark

[@iTeerRex]

Having done no casing myself, I wonder if lost-wax-casting would’ve been easier, or worked at all. Glad it worked out ok though 👍 50s to 70s looks like a wonderful time period. No public computers but technology advanced enough for a very comfortable life.

[@Preso58]

Lost wax casting allows for almost unlimited complexity for the finished part. There is no need for draft and you can have undercuts and hollow forms but it is very equipment and material heavy. I just don't have the gear to use that method at present. It is something I would like to try though. Regards, Mark

[@iTeerRex]

@@Preso58 I thought there was a reason, but not knowing enough, I didn’t hazard a guess.

[@didieryvron149]

Hello Mark, nice idea this lava rocket, but now indeed you need a Sputnik for the completion 😂😂

[@Preso58]

Now we're talking. That's starting to get into "Atomic Age". Regards, Mark

[@MyMiniHomeWorkshop]

Tough gig casting that, I don't envy you on that one, quite a nice outcome though. 👍 Just as a thought, it's been suggested to me that you can use printed bits in the same way I use foam to make lost foam castings, I did have a quick go at it a while back without much success, but we came to the conclusion that the printed parts I was trying it on had too much infill 🤔 PS: Did you receive that sticker I sent you, I still haven't received yours yet, but that doesn't surprise me. I sent one to Rusti the day after I sent yours and he received that 2 weeks ago.

[@Preso58]

Thanks Paul. I did receive your sticker and I have included it in part 2 of this build. It should be out next weekend. I got a bit cocky on that casting. The last two that I did worked first time but that almost never happens. Regards, Mark

[@MyMiniHomeWorkshop]

@@Preso58 Glad you finally received it, I just wish that yours and Matty's from Matty's Workshop would show up here, Aust Post is so slack in getting mail over to here, once it arrives here I'll have it within a day or so.

[@CreaseysWorkshop]

Those things can really do a number on a beige carpet. Don't ask how I know!

[@Preso58]

I can imagine. Stable and bullet proof they are not. Regards, Mark

[@nobbysworkshop]

Thoroughly enjoyed the video Mark. Very nerve racking watching you set the mould. Many years ago I bought my wife a genuine Larva Lamp. We discovered that the don't mix very well with small children. Silly question, could the boss and legs be cast separately? Perhaps a tongue and groove to attach the legs? Just thought. Cheers Nobby

[@Preso58]

I did consider making the legs as separate pieces but the joint was always going to be tricky. The lamp is now finished and it looks great. They are a fairly unstable and wobbly design, especially with the original circular spun aluminium base but now it has a wider stance it should be safer. Regards, Mark

[@skypatrol716]

My bum puckered when you split the mold 😂 but good work arounds on all issues.

[@Preso58]

Yes, it was exciting at first and then it all went bad. It's part and parcel of metal casting though. It's best not to take it personally. Regards, Mark

[@scottkramer7431]

I think you could cast the complete bottom section. The light bulb just needs to be able to heat the coiled wire in the base of the lamp. The mass of a cast base may cause the lamp to take longer to reach steady-state, but it should still get there.

[@Preso58]

I just completed the lamp yesterday and due to changing out the bulb holder, the heat bulb now sits about 8mm lower in the lower section. It nearly doubled the time it took to get the wax melted so it seems that there is a very narrow window in terms of heat distribution. I will need to raise the bulb closer to speed up the start. I guess it doesn't matter too much if you are going to leave it on for an extended period though. Regards, Mark

[@Je.Suis.Flaneur]

What do you do to mull your sand?

[@Preso58]

I made a horizontal drum type muller based on a design by luckgen1001. It works great. kzbin.info/aero/PLbPzkHRZCQB-roCizMpRhQXyEPT7NoFw1 Regards, Mark

[@markfoster6110]

Green sand? Or epoxy type sand ? Have you any metal spinning videos . Thanks for your time

[@Preso58]

I used green sand for the drag (bottom box of the mould) and epoxy sand for the core that filled the coped down section in the drag. The top box (cope) was all green sand. I have done a little metal spinning but it was way before I started making KZbin videos. I made some brass bezels for some model locomotive windows. Regards, Mark

[@sheph7]

WOW, impressive work, very nice. Any consideration given to making the part in 4 pieces? That would have been my first inclination. Scary Workholding for sure.

[@Preso58]

I did consider having separate fins but I abandoned that idea when I decided not to attach the fins to the original lamp body. The joint line would have been a three dimensional affair which probably would have needed a CNC tool path. Regards, Mark

[@erniecamhan]

Hi Mark, I was expecting that, could you have put a small rod on each leg to allow any gasses to escape and poured the metal into the center hole

[@Preso58]

I should have vented the mould at the ends of the two legs that didn't fill properly but I got cocky and thought it wouldn't matter. Turns out my intuition was correct. Regards, Mark

[@PatFarrellKTM]

Cool effort. I say bead blast the lower fins. The casting was amazing. Did you consider making a bigger(longer) fin pattern, so you could plan to machine off the ends and top corner to "hide some sins" in the actual casing process?

[@Preso58]

As it has turned out I did fully polish the casting and it turned out fairly well. There is some minor porosity and pitting but overall it is a good match for the rest of the parts. To be honest, I hadn't considered the mould not filling completely. In hindsight I should have vented the two cavities where the legs didn't completely fill but you know what they say about hindsight! Regards, Mark

[@robertparker2420]

Looking at the way the two short fins didn’t fill I think it might have been venting that was the problem. Perhaps if you had run a wire down into the top of the fin it would have fully filled. All in all a very nice casting though.

[@Preso58]

Yes, I thought about venting but I got cocky and decided that there was enough head pressure to fill the mould completely. I made the metal extra hot too, around 800C. Regards, Mark

[@rexmyers991]

W O W. ! ! !

[@bw6378]

Technology connections did a long video about these. He concluded the fluid is dry cleaning fluid (aka brake cleaner) and as you said its paraffin wax.

[@stujd1539]

From a geological perspective, the original designer called them the wrong thing. He should have called them Magma Lamps as the action is the same process that molten rock (magma) undergoes within the earth's crust. If the lamp spewed its contents all over the desk, then Lava Lamp would be appropriate.😀😀😀

[@Preso58]

That's a valid observation. I remember watching a documentary about the Disney animators who worked on the lava sequence for Fantasia. It was absolutely fascinating how they created the finished sequence and it was all hand drawn on cells. Regards, Mark

[@dougaldhendrick3497]

Perhaps some breathing holes on fins would allow full fill..

[@Preso58]

Yes, and I did almost add vents to those areas but I thought that the height of the mould would give me sufficient head pressure to avoid an airlock. Possibly the greensand was a bit damp or maybe I rammed the cope too hard. However, I have been able to salvage the part by adding some extra rocket motors. You will see the upgrade in the next episode. Regards, Mark

[@Chromevulcan]

KITTY!

[@Preso58]

Yes, the cats sometimes make cameos that I don't notice until editing time. Regards, Mark

[@IM-qq3jf]

Hey Presso, I love your Videos, but iam astounded at the amount of time and money spent doing this when you could have just bought the genuine Mathmos Rocket lamp, and used your time and money on all of your other projects. I personally have the genuine lamp, its great.

[@skypatrol716]

Its the journey, not the destination.

[@markfoster6110]

​We would not have anything to watch and learn great yeacher this guy . @@skypatrol716

[@IM-qq3jf]

@@skypatrol716 Yes thats true !

[@Preso58]

Prompted by your reply here, I address that issue in part two of this series. Unfortunately, items made in the UK and USA don't always ship to Australia where I live. Sometimes the shipping cost is as much or more than the item cost. At the time I started on this project, Mathmos were not shipping to Australia but I just checked and there is now an Australian website but it is not complete. Still, it would have been over $200 if I could get one and my total outlay for this project was less than $50. I also wanted to work on a casting that required coping down since I had never tried it before. Also, the finished project is unique. I guarantee, there isn't another like it. Having said that, I just shelled out over $250 for a mid century modern clock on Etsy. It is made by Royal Enamel in the UK and they do ship to Australia. It is a lovely clock and not something that I could easily make myself. Hopefully I will show it in the final video in this Mid Century Modern series of videos. Regards, Mark

[@IM-qq3jf]

@@Preso58 Hi Mark. Wow, thank you for such an amazing comment back to me. It all makes sence to me know. I notice when looking through you list of videos, you have made a good number of beautiful lamps, and I will have to watch them through. That is a favorite hobby of mine. Actually, I have made 2 Australian Model lighthouses. A generic QLD Lighthouse &( Mersey Bluff in Tasmania ) & I,am starting on ( Nobbies Lighthouse in Newcastle NSW ) my home town. I have thoughts of making a video of them. Thanks so much for your time and brilliant videos. Ian T.

[@lloyd4768]

Something like that would almost be better casting using the lost wax process..

[@Preso58]

That is true but I don't have the facilities or materials for lost wax casting at present. It's something I would like to try but it is a fairly equipment heavy alternative. Regards, Mark

[@ronkennedy213]

Yeah, another of Mark’s vid’s

[@jdmccorful]

Love it! Thanks for the look.

[@seabreezecoffeeroasters7994]

Four legs good, Two legs bad’.... ... 3 Legs odd 🤣