lead ballast

[steven smith 6Participant @stevensmith6]

Has anyone made one?

I'm going to make one, and would like tips for using a timber form

[steven smith 6Participant @stevensmith6]

making a lead bulb keel

[Paul TParticipant @pault84577]

Steven

Using molten lead can be very dangerous and you must ensure that all parts of the mould are perfectly dry as contact with any moisture will have explosive results.

Make the mould in two halves with a large pouring hole and two pressure release holes in the top, paint the inside of the mould with carbon black (or an emulsion of soot & water) as this will act as a release agent and prevent the lead from sticking to the mould.

Wear flame proof overalls, welding gauntlets and a full face safety shield.

Paul

[Terry PlumridgeParticipant @terryplumridge66794]

Hi Steven,

I have used this program to make a bulb weight using lead sheet. Excellent end result and no molten lead to worry about!!

Terry. **LINK**

[Bob Abell 2Participant @bobabell2]

Hello Steven

My last bulb keel was made in two halves

I gouged out half the bulb shape in a block of wood ( fence post) and cast two pieces

Don't forget to also cast in a slot for the keel fin…..then bolt the two halves together

As Paul mentions…..Boiling lead is highly dangerous……Safety goggles are a must

Bob

[Bob Abell 2Participant @bobabell2]

Just found a couple of pictures of a vintage yacht keel, I made a few years ago

Strong wooden box, with wooden mould mounted in correct orientation, waiting for the plaster to be poured in.

It`s vital that the plaster to be perfectly dry before mouring the lead………Goggles!

Here`s the finished casting….

Bob

[Bob Abell 2Participant @bobabell2]

Here`s a split mould being cast in the greenhouse

Note the gloves and two handled pan ( G-Clamp)

Bob

[Bob Abell 2Participant @bobabell2]

Melting the lead in the kitchen when the wife has gone shopping!

Note the protective gear

A G-Clamp is used as a second handle on the pan as a safety measure

Don`t worry…..This is a scrap pan for lead only

Bob

[Kimosubby ShipyardsParticipant @kimosubbyshipyards]

Steven,

as both Paul and Bob stress, safety must be paramount – molten lead is very hot (about 328'C) and will ignite wood, paper, lino, worktops etc. It is also very unstable when molten in a pan due to the mass rolling about (2 -4Kg). Bob is most correct in saying use a pan with two handles, these must be the bolt on type due to the heat, though in a domestic kitchen – not for me. The pan also requires a pouring spout. I've seen body damaged caused by molten lead – guy was only making 6oz fishing weights, pan wobbled and he made a grab, down his leg – not nice at all.

If you have any doubts, bite the bullet and buy one, or make one from lead sheet bolted together, then hammered to shape. Molten lead is not for the feint hearted!

I have made several lead bulbs for IOM and MH, and will soon be doing one for a 36R same as Bob's above. All mine have been made using a split mould created with plaster of paris and held rigid in a wooden former box.

To create the mould you need a plug. Once the mould has been made and hardened at room temperature, cook it dry, literally gas mark 5 for 2 hours, raising the gas mark setting over about an hour.

Before using the mould ensure there is an adequate air hole(s) and that the entry hole is large – lead will solidify about the entrance hole and block it quickly. I also pre-heat the mould to very hot (gas oven Mk 7) prior to a pouring.

Expect to make several attempts to get it right.

NEVER be in a rush to open the mould – leave it overnight to cool down – it's extreemly hot and unforgiving!

Kimosubby.

[Andy CParticipant @andyc56856]

As an alternative, and also because I am not in a position to make my own, Graupner provide various ballast bulbs via a number of very well known model shops. They are also very inexpensive to purchase.

Regards

Andy

[Sm shogunParticipant @smshogun38232]

I make a mock up in wood and coat it in polish, then lay it in a box and suspend it so it isn't on the bottom. Use either plaster of paris or ordinary finishing plaster used to plaster homes, half fill the box with this plaster by making it thin enough to pour, then allow it to fully dry.

Remove the plug you have made from the mould and polish it again, sand the top of the half mould perfectly flat and reinsert the plug, cover the bottom half of the mould plaster with cling film or similar, then refill the mould to the top with more plaster. You will now have a plaster mould in two halves for casting multiple lead castings.

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