How to Use Mud to Mold Brass

Make a mold from mud to cast your favorite brass piece.

Brass is made with a combination of copper and zinc. It has corrosion-resistant properties making it a popular metal to use for machine parts as well as musical instruments. You do not need expensive clay or wax to mold brass. Instead, use mud to mold brass and other metals. Mud forms a mold that is resistant to the heat of molten brass and strong enough to hold the metal.

Things You'll Need

• 4 plywood sheets, 1/2-by-4-by-10 inches
• 4 plywood sheets, 1/2-by-4-by-5 inches
• Table saw
• Hammer
• Wood nails
• Talc powder
• Paint brush
• 1-inch PVC pipe, 5-inch length

Instructions

1. Cut a 1/2-inch plywood sheet into two 4-by-10 inch pieces, using a table saw. The pieces are the side pieces. Cut a 1/2-inch plywood sheet into two 4-by-5 inch pieces, using a table saw. The pieces are the top and bottom pieces.

2. Position the top and bottom pieces vertically and parallel to each other. Position the side pieces vertically between the top and bottom pieces. The pieces make a rectangle. Nail through the edges of the side pieces into the edges of the top and bottom pieces, using a hammer and wood nails. Repeat until you make two wood frames.

3. Fill the frame halfway with mud. Insert the brass object into the frame. Pour mud around the brass object until the frame is full. Use a flat object to level off the excess mud. Half of the brass item is covered in mud. The other half of the brass item is exposed.

4. Let the mud dry for 12 hours. Sprinkle talc powder over the dried mud and brass object. Brush the talc powder around the dried mud and brass object, using a paint brush.

5. Insert another wood frame on top of the first frame. Pour mud into the frame. The mud covers the dried mud and brass object in the first frame. Use a flat object to level off the excess mud. Insert a 1-inch PVC pipe with a length of 5 inches into the mud next to the object. The pipe makes an insertion hole used to pour the brass into the mold. Let the mud dry for 12 hours.

6. Remove the pipe from the dried mud. Lift the second frame off the first frame. Remove the brass object from the dried mud. Place the frames on top of each other. Pour molten brass into the insertion hole to cast the brass.

Tips & Warnings

• Wear protective gloves, goggles and mask when handling a table saw.

References

• Stanford University: Brass
• All India Artisans and Craftworkers Welfare Association: Dhorka
• YouTube; Metal Casting at Home Part 1 Backyard Foundry; Oct. 22, 2008