I have just spent the afternoon making a heap of weights.
For those of you who have thought about it and may try it at some point, I can give you a few tips.
Firstly get your lead together, It doesn't really matter where you get it from, try the neighbours roof if you are really stuck.
Just one thing DO NOT Use old lead from Car batterys it is toxic and generally nasty.
the cleaner the lead the easier the process will be for you.
This is a heap of old roofing lead that I found around the place.
It wasn't the cleanest and I spent a lot of time skimming the scum off the lead, I recommend clean lead.
Before you even start melting the lead down lets talk safety.
Safety gear, Please don't take short cuts with this stuff, Its not worth it. Spearing fish is much harder with one or no eyes.
The last time I used this gear a piece of lead had some water trapped inside, I did not realise this and had just put it in the crucible when it exploded.
Had I not been wearing all the gear I would have lost my sight and been burned by lead splash.
Fortunately, my boots long pants and heavy cotton shirt buttoned up to the neck saved me from being burned and the face shield was covered with lead splatter.
I also use a Disposable respirator mine is a 3M model but any type that is suitable for welding/metal fumes is suitable. Don't do this indoors.
You can also see my gloves and a can of silicone mould release. I only used these fabric and rubber gloves for cutting the lead sheet up.
I used heavy suede welders gloves for the hot work.
Here is the process in action.
I have two moulds to speed things up.
In the foreground are the moulds full of lead and some leads that I have just tipped out onto the wood.
You will find that the finish on the weights is better after the moulds reach working temperature.
I also put a small piece of candle wax into the molten lead to bring the scum to the surface, small means about the size of a pea.
What I haven't shown here is the piece of metal that I use to skim the rubbish off the top of the lead.
anything will do but remember once used for this, you can't eat off it again.
Here is the process I use step by step.
1. Don all the safety gear and fire up the burner.
2. Add some lead to the crucible and wait till it melts, add some more, do this slowly and carefully.
3. Once you have enough lead melted put a small piece of wax into the pot and stir it, all the bad stuff will float to the top and can be skimmed off.
4. Preheat the mould , by pouring a weight.
5. Let the weight cool and tap it out onto a wooden block.
6. Pour the first weight.
7. Repeat steps 2-6 until all the lead is gone.
You could end up with a lot of leads...
My tips
As you can see, I have a piece of Aluminium plate about 4mm in thickness,I use this as a heatsink.
The lead and the moulds cool faster when laid on this.
Get a big can for the lead scum it is heavy and poisonous.
No matter how hot the day is don't be tempted to take off the safety gear, one drop of sweat will make the lead in the crucible explode and you won't like that.
I use a wooden stick to stir the lead if the lead starts to turn blue and the wood smokes, the lead is too hot, add more lead to bring the temperature back down.
When pouring lead slow and steady is best , too fast and the lead may splash causing damage and pain.
I always put the first few leads that I cast back into the crucible as the finish is not as good, once the mould is up to temperature keep up a steady rythym of pour, add lead, skim, tap out, pour......and the finish will be better.
Have fun and stay safe.
For those of you who have thought about it and may try it at some point, I can give you a few tips.
Firstly get your lead together, It doesn't really matter where you get it from, try the neighbours roof if you are really stuck.
Just one thing DO NOT Use old lead from Car batterys it is toxic and generally nasty.
the cleaner the lead the easier the process will be for you.
This is a heap of old roofing lead that I found around the place.
It wasn't the cleanest and I spent a lot of time skimming the scum off the lead, I recommend clean lead.
Before you even start melting the lead down lets talk safety.
Safety gear, Please don't take short cuts with this stuff, Its not worth it. Spearing fish is much harder with one or no eyes.
The last time I used this gear a piece of lead had some water trapped inside, I did not realise this and had just put it in the crucible when it exploded.
Had I not been wearing all the gear I would have lost my sight and been burned by lead splash.
Fortunately, my boots long pants and heavy cotton shirt buttoned up to the neck saved me from being burned and the face shield was covered with lead splatter.
I also use a Disposable respirator mine is a 3M model but any type that is suitable for welding/metal fumes is suitable. Don't do this indoors.
You can also see my gloves and a can of silicone mould release. I only used these fabric and rubber gloves for cutting the lead sheet up.
I used heavy suede welders gloves for the hot work.
Here is the process in action.
I have two moulds to speed things up.
In the foreground are the moulds full of lead and some leads that I have just tipped out onto the wood.
You will find that the finish on the weights is better after the moulds reach working temperature.
I also put a small piece of candle wax into the molten lead to bring the scum to the surface, small means about the size of a pea.
What I haven't shown here is the piece of metal that I use to skim the rubbish off the top of the lead.
anything will do but remember once used for this, you can't eat off it again.
Here is the process I use step by step.
1. Don all the safety gear and fire up the burner.
2. Add some lead to the crucible and wait till it melts, add some more, do this slowly and carefully.
3. Once you have enough lead melted put a small piece of wax into the pot and stir it, all the bad stuff will float to the top and can be skimmed off.
4. Preheat the mould , by pouring a weight.
5. Let the weight cool and tap it out onto a wooden block.
6. Pour the first weight.
7. Repeat steps 2-6 until all the lead is gone.
You could end up with a lot of leads...
My tips
As you can see, I have a piece of Aluminium plate about 4mm in thickness,I use this as a heatsink.
The lead and the moulds cool faster when laid on this.
Get a big can for the lead scum it is heavy and poisonous.
No matter how hot the day is don't be tempted to take off the safety gear, one drop of sweat will make the lead in the crucible explode and you won't like that.
I use a wooden stick to stir the lead if the lead starts to turn blue and the wood smokes, the lead is too hot, add more lead to bring the temperature back down.
When pouring lead slow and steady is best , too fast and the lead may splash causing damage and pain.
I always put the first few leads that I cast back into the crucible as the finish is not as good, once the mould is up to temperature keep up a steady rythym of pour, add lead, skim, tap out, pour......and the finish will be better.
Have fun and stay safe.
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