Introduction: Crayon Wrapper Wine Stopper

I took 33 empty crayon wrappers, cast them in polyester resin, then turned them on the wood lathe. I also had a few bumps and hiccups along the way...

Step 1: The Casting Process

I made an Instructable about my vase from melted crayons a few weeks back. During that process I learned a trick for getting the wrappers off crayons by freezing them first. I saved a few of the wrappers as they just had an interesting look to them!

Note that this casting will be done in an 8oz mixing cup. It provided the correct shape for a stopper and also eliminated the need to make a special shaped mold.

I used 33 wrappers, as they fit well in the bottom of the mold. To hold them in a cylindrical shape, I added a rubber band around them. My plan was to cast them in epoxy resin. (Let me tell you about the the best-laid plans of mice and men...)

I used about 4 oz of resin, which would net me a 2" square casting.

So... This was interesting. 4oz is not a large casting, but the resin cures via an exothermic reaction. While it's not a ton of resin it got very hot because the heat was contained in 34 containers (the mixing cup + 33 empty wrappers) and there wasn't enough air to cool the casting.

Basically, it got hot. Really hot. It ruined two casting. Anyway... 3rd time was a charm, when I switched to different type of resin. (Polyester instead of Epoxy)

Step 2: Prepping for Turning

After the 3rd casting was sufficiently cured, I cut it up at the band saw.

The diameter of the casting was a hair too big for my chuck jaws, so I had to cut the cylinder into a cube, so I could mount the cube on the lathe and turn it back into a cylinder. It's all very technical.... :)

For bottle stoppers, I use a kit with a threaded mandrel and stub drill bit.

You drill a hole in the bottom of the piece, then remove your chuck, and replace it with a bottle stopper mandrel. It has a self tapping threads that you twist the blank on to, thus achieving a strong hold for turning!

After you've made a few hundred of these, it becomes second nature. Don't ask me how I know that!

Step 3: Turning and Finisings

Turing a wine stopper is easy work, but polyester resin is nasty stuff. A lot more brittle than epoxy resin. I decided to switch from my traditional steel wood turning tools to a carbide cutting chisel.

Even with the carbide, it breaks off like little glass shards and is very hard on the hands. Before you ask, gloves at the wood lathe is a good way to lose a digit.

After turning, I had a pretty cool looking item, but I still needed to sand and polish it.

I wet sanded to 400 grit and then I used my acrylic polishing pads (micro mesh pads) to take it up to 12000 grit.

The difference was amazing. It turned completely translucent and had an effect almost like glass! I'm more than happy with this little trinket and might have to change my feeling on turning polyester resin in the future!

Thanks for looking!

Comments

author
kishinmaster made it!(author)2016-04-29

Congrats on stealing a project from Peter brown

author
ChickBang made it!(author)2016-08-27

The only comment that made me laugh!

P.S.: Peter B's youtube user is kludge1977 hmm... suprisingly similar

https://www.youtube.com/user/kludge1977

author
kludge77 made it!(author)2016-05-01

I am Peter Brown! thanks for looking out for me dude, I appreciate it!

author
KellyCraig made it!(author)2016-04-29

Cool ible. I wonder what would have happened if the crayon casings, each, had dowels in them. That is, would they still have gotten so hot.

I used to buy my two part epoxy in [two] five gallon containers. A couple times, doing a big pour, I dallied and, quickly, learned you could melt a cup and produce a lot of heat [and panic].

author
Lineakat made it!(author)2016-04-26

really awesome project! :)

author
Yonatan24 made it!(author)2016-04-23

By the way, What Drill-Bit did you use for drilling into the Epoxy while it was on the Lathe?

It looked like a Twist-Bit, But I thunk it would make more sense to use a Masonry-Bit since Epoxy is supposed to be pretty hard...

author
Yonatan24 made it!(author)2016-04-23

If the Epoxy heats up because of a chemical reaction that makes it cure, What about trying to melt crayons in the heat of the chemical reaction of the curing Epoxy? :)

(Hopefully that makes sense)

author
ClenseYourPallet made it!(author)2016-04-21

Turned out really cool! Another great project

author
kludge77 made it!(author)2016-04-22

Thank you!

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Richard2926 made it!(author)2016-04-21

wow dude, awesome

author
kludge77 made it!(author)2016-04-21

thanks!

About This Instructable

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Bio: Come spend some time in the shop. I'm a hobbyist woodworker and professional computer geek in Northern California. I guess my projects will vary ... More »
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