Instructables
Picture of Cast Aluminum Belt Buckle
About a year ago I had a Thrift Store Prom Party to attend, and among
the many other jems I found was a studded belt with the Mistfits logo
as the buckle. It was cool, but I wanted to make my own buckle to
personalize it some more.
Here's my process....

Things used:
Epilog Laser Cutter
TechShop San Jose
SJSU Foundry
MDF
Dremel
Drill
Files
Resin Bonded Sand
alcohol/graphite
High temp tar sealant
Aluminum
wood and threaded rod
PC-7 epoxy
 
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Step 1: Make the Pattern

Picture of Make the Pattern
IMG_0021.jpg
Using one of the lasers at TechShop, some scrap MDF, and a .jpg that
I grabbed from Google Images, I cut and etched my pattern. Using a
Dremel, I accentuated some of the three dimensional details (made the
eye sockets deeper and rounded the edges). Modifying your pattern is
almost always easier than making changes once its cast in metal. 
EthanJP9 months ago

How much for a custom one?

TSSJ-ryan (author)  EthanJP9 months ago

sort of depends on the amount of detail and how long it takes me to make it. I'd charge about $50-60 for the one in this instructable. send me a PM with your idea and I can give you a better estimate.

EthanJP TSSJ-ryan9 months ago

One of these

redriver.jpgbb.jpg
Wingloader1 year ago
Very COOL. I'm jealous. Unfortunately, I only have like one or two of the required items available to me. :-)
TSSJ-ryan (author)  Wingloader1 year ago
Might you make your own mini foundry?

http://www.instructables.com/id/Build-a-foundry-and-sand-cast-aluminum/
http://www.backyardmetalcasting.com/

if so, best of luck to ya!!
=D
I hope to *will* build my own one day ;)
TSSJ-ryan (author)  TSSJ-ryan1 year ago
http://www.instructables.com/id/DIY-Mini-Forge/

=D
shalffon1 year ago
Howard Wolowitz would like this, good job!
zomfibame1 year ago
Pretty cool buckle.
TSSJ-ryan (author)  zomfibame1 year ago
danke
LobosSolos1 year ago
Had you considered building the hook to close the belt and the bracket to attach the buckle to the belt into the pattern?
TSSJ-ryan (author)  LobosSolos1 year ago
The belt idea came to me after the metal was already cast hahah
kcarley1 year ago
How do you make resin bonded sand? If it was already provided for you, do you have the ingredients, recipe, or places it can be purchased?
TSSJ-ryan (author)  kcarley1 year ago
I believe it was some sort of three-part mixture. Sand, resin, and some catalyst.
Not sure of all the exact brands. It was some really old barrel that the SJSU foundry
just had laying around, and no one really knew.
As for purchasing... I'm not really sure, have not bought the stuff myself, sorry.
Eh Lie Us!1 year ago
I'm curious but why did you destroy the mold?
TSSJ-ryan (author)  Eh Lie Us!1 year ago
The mold is fragile, and only good for one casting.
If you look closely you can see that the bottom right
bone as far less detail. This is due to an accidental
spill of iron onto the vent of that particular bone.
When I opened my mold for the first time all that it
contained was this single iron bone haha. =\
ironBone.JPG
Have you got a way of doing this without destroying the mould?
That's part of most molding. You've still got the original pattern so you can just remake the mold.
TSSJ-ryan (author)  LobosSolos1 year ago
For most metal castings the mold is the consumable which must
be made for each casting. Reusable molds are typically made to
make a wax casting, for the metal casting process. =)
minicapt1 year ago
You might exercise caution where you wear that buckle, as it is derived directly from the cap badge, or "motto", or the "Queen's Royal Lancers". It entered existance as the "motto" of the 18th Regiment of Light Dragoons in 1759, who were renamed 17th Regiment of Light Dragoons in 1761, and finally 17th Lancers in 1822.
http://en.wikipedia.org/wiki/File:17th_Lancers_Badge.jpg

Cheers
Not only does the skull & crossbones far predate the Lancers as the accepted pictograph for death, but stylistically those two skull & crossbones sets are completely different with the above being much more anatomically correct than that used by the Lancers.
its just a skull and crossbones here in the states. doesnt mean anything else.
WHAT HAPPENED TO THE MISFITS BUCKLE!?!?!
TSSJ-ryan (author)  LucDaRocka11 year ago
gave it to a friend =)
Oh.... Good for him... :( If u still had it laying around and didn't want it.... I would ask if you could ship it to me...