Creating a Solid Copper Sledgehammer Head: A Unique Project

TLDRLearn how to create a one-of-a-kind solid copper sledgehammer head using fusion 360, sand molding, and copper casting. The process includes designing a core mold, melting copper, ramming up a sand mold, casting the copper ingot, machining the faces, and attaching a hickory axe handle. The result is a stunning and functional piece of craftsmanship.

Key insights

🔨Creating a solid copper sledgehammer head requires advanced design and casting techniques.

⚙️Fusion 360 is a powerful tool for designing patterns and molds for metal casting.

🔥Melting and casting large amounts of copper requires time and specialized equipment.

💡Adding sodium silicate to sand creates a hardened core mold for complex shapes.

Machining and polishing copper can create a beautiful finish for the final product.

Q&A

Is copper a good material for a sledgehammer?

Yes, copper is softer than steel, making it ideal for tasks that require less force and precision.

Can I use a different type of metal for the hammer head?

While copper is used in this project, other metals like bronze or aluminum can be used as well.

Do I need specialized equipment to cast copper?

Yes, melting and casting copper requires a high-temperature furnace and safety precautions.

How long does it take to make a solid copper sledgehammer?

The process can be time-consuming, with steps like designing, casting, and machining taking several hours to complete.

Can I use the sledgehammer for heavy-duty tasks?

While the copper sledgehammer is durable, it is best suited for light to medium tasks to avoid deformation.

Timestamped Summary

00:00The video starts with the creator finding an old sledgehammer head in their toolbox and getting inspired to make a solid copper version.

00:34They use Fusion 360 to design a pattern for the sledgehammer head and create a sand mold.

01:20A core mold is made with a mixture of sand and sodium silicate to create a hollow center for the sledgehammer head.

01:54The copper is melted, poured into the sand mold, and left to solidify.

03:41The creator shows a copper ingot they made previously and decides to use it for the sledgehammer project.

04:05The copper is melted and poured into the mold, forming the sledgehammer head.

05:11A patreon account is mentioned for viewers interested in supporting the creator's work.

06:33The mold is opened, revealing the solidified copper sledgehammer head.