That other ankh/spade TARDIS key

[Cardinal Hordriss]

The process is fairly simple and has been around for thousands of years. We teach it in schools in the course of a day and kids get to make things in that time. With practice you get better at it, learn the moods and moves of the metal, what is and isn't possible with this particular method. I spend most of my time at work dealing with the admin and making props in other ways so I'm a little out of practice but the finished key isn't too bad.

My next plan, with the help of our tech guy is to make a computer model of the original prop, now the reference thread has more clear images and pics of a superb replica, to 3D print in the office and then cast. Our 3D printer is very good but the striations from the printing process are visible so the trick will be in the finishing process on that model as the sand is able to pick up the detail of a fingerprint the striations will be visible on the cast piece.

[Cardinal Hordriss]

Bit of an update -

I've just finished 3D printing a much more accurate version of this key based on the clearer and more detailed pics that have appeared n the reference thread.

This model will now replace the master in the previous posts but the method is the same. I'll try to remember to take more pics of the finishing process and pouring etc. this time round.

[Cardinal Hordriss]

Here is the metal being poured by my colleague John (because at more than 1000 degrees I won't go near the damn thing) -



Cracked open after a few minutes -



Pre-feckling (feckling is the technical term for filing, sanding and generally tidying up) -




It was what we call a good pour, not perfect but I decided to go ahead and feckle it anyway, pics to come.

[Davros Skaro]

WOW, that looks just brilliant.

Chris.

[Volpone]

Really, if you're doing a handmade hobby sandcasting, the imperfections are almost a feature.  It makes it more like the actual props as opposed to a flawless key, spit out by a machine. 

[Scarfwearer]

This is really interesting! Thanks so much for showing us how it's done.

[Cardinal Hordriss]

Here it is so far pictured next to the Mooncrest key. In the second picture I have highlighted the main flaw with this model which was caused by sand sticking between the crazy paving of the master when it was removed.

[Cardinal Hordriss]

This is the second attempt. A bit too shiny for my camera but you get the idea -

[karsthotep]

Looking good man.

[Cardinal Hordriss]

For some reason I haven't been able to replicate the success of the first couple we did but I thought I'd post these pics so you can see just how much variation is possible even when using the same master with 2 part sand casting.

[elkad]

Found a video on YouTube on how to make a door key.

https://www.youtube.com/watch?v=d1tkmacAwd0