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The plastic door number on my flat door was damaged, so I decided to make a new one. I will make it of brass using lost foam casting technology.

Step 1: Making a Mold

Cutting a polystyrene foam pattern and making a mold

Step 2: Melting and Pouring

Melting and pouring brass. After this step it's time to open a flask.

Step 3: Cutting and Sanding

After I cut several pieces and sand the number, it is ready to be put on the flat door.

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More by DuralM:White Bronze - Home Melting Techniques. High Leaded Bronze Production Cast Brass Door Number. Lost Foam Casting Making a Cast Brass Belt Buckle 
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