Casting an inlay?

[A.Merrill]

    I have never done this and have know idea how.  How would a guy go about making a mold to cast a inlay? Say something like a thumbpiece for a Fowler that is in relief. I would like to use coin silver if possible, but how would you go about melting it down? This would probably be a one time thing so I don't want to spend to much on it.    Thanks for any info.    AL

[David Veith]

Just buy a silver coin the right size and cut it out with a jewelry saw. A good tool to own if you don't all ready. A $ 20.00 bill for the saw and up to $20 on the coin save all of your scrap. Normally they cut there piece out on a board that is clamp to a bench. the board has a v notch cut out to support what ever you are cutting. Buy good blade. Do some hunting on the board it might be in the old one was a list of good to Grade blades.
 PS a lot of people will use a piece of paper as a pattern and just glue it to what ever you are cutting out. Stop a a coin shop or pawn shop and as for junk silver coin to buy. use some home made nails it in stall leave it a little proud and file it of as you do final shaping.
David

[Jim Kibler]

I believe he asked how to do a RELIEF inlay such as often seen on a fowling piece.   To make this, you have a couple choices.  Cut it out and file / chisel it to the shape you want.  Make a master out of a more favorable material to carve and shape and then make a casting off of this master.  It seems the English used a very fine sand that gave excellent detail.  Most sand casting done today is much coarser.  Another option would be to use investment casting.  You have a few options here, but it would require a lengthy explanation.  I'll explain futher if you're interested.  A final option would be to use the Delft clay method.  Seems I recall a good explanation or tutorial of this process from Dave Person.  Hope this helps. 

[Acer Saccharum]

If you have a master, you can use cuttlefish bone to make a mold and cast silver in it. Check YouTube for cast with cuttlefish bone.

[Ed Wenger]

I think Jim is correct about the tutorial, you might want to check the archieves...  Might be a little more $ than what you wanted to invest.  You might want to check a local school / college's art department, they might agree to a one time cast for a smaller amount.  Just a thought...

          Ed

[bob in the woods]

I did as Acer said. Made a master for a front fowler sight [ man's face with big nose ] out of " ..skullpy..sp? "
a modeling clay that you bake after to harden it.  It was a learning experience, but entirely doable.

[A.Merrill]

     Thanks for the help guys.    Between Dave Person tutorial and You Tube it made it look very easy.  I think I will go with the clay, looks like things come out smoother than with cuttlefish bone, that was the way it looked on You Tube. But there again to clay is $48.00 to cuttlefish bone $27.00    Didn't see anything on investment casting.  Thanks again guys    AL

[Curt Larsen]

On my first build, a kentucky pistol, way back in the 60's I made custom ramrod thimbles and a nosecap from coin silver.  A dentist friend who did lost wax casting gave me some of the wax they used in the process and I made my models from the wax.  I gave him the models and he set them up the proper sprues.  They came out beautifully.  I wish I still had access to the dentist friend and his help.  There were more silver coins around back in the 60's.  Now you can get "junk or scrap" silver coins on ebay. 
Curt