SpudFiles

I have been fiddling around with epoxy casting lately and I discovered a new technique that could help the forum. What I came up was that you can use a variant of lost foam casting to create intricate air channels inside the block of epoxy. All that is needed is a foam form of the air channels you wish to create. I recommend the pink insulation foam from lowes/home depot because its smooth finish. Then you cast the block around it. It is very important to remember that foam is buoyant and you must account for that. When the block has cured all you have to do is pour paint thinner/acetone/gas/ carb cleaner or anything else that dissolves foam down into the block and it will eat all the foam leaving you with nice air channels. Edit: I also recommend using a metal file for creating the foam shape,it gives nice texture and doesn't take off material too fast.


I hope this has helped any would be epoxyists and I also hope this thread could turn into a thread about epoxy casting tips.

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do you think epoxy has adequate structural properties to be used unsupported as a valve body?

It all depends on how thick your block is and channel placement. Mine holds up fine but I can't guarantee that about all designs.

So, did you ever get that mould out?

I agree with spudblaster, for higher pressure larger bore applications, metal inserts/casing should definitely be considered.

So, did you ever get that mould out?

No, I had to make a new one but I got that one out and I am very happy with it.

Epoxy is very much one of those "if at first you don't succeed..." sort of techniques

Epoxy is very much one of those "if at first you don't succeed..." sort of techniques Wink

That could explain the row of failed epoxy work I have been accumulating.