Step 1: Materials and Tools
Pewter Ingot (Make sure you use NON-LEAD pewter!)
Black Pewter Patina
Silver link or wire
Fine Steel Wool or Buffing Wheel
Chain or String
Hot Pot, or Crucible and Torch
Safety Gear (Face shield, leather gloves)
Wood Carving Tools (CNC, Rotary Tools, Mill, Knives, etc)
Step 2: Design
Step 3: Making the Mold
Step 4: Casting Pewter
A few safety notes: I have read online that it is a good idea to have your mold on top of sand in case the liquid pewter spills, it can catch it and not react in a violent way. Apparently, the molten pewter must not come in contact with anything with moisture in it, or it can explode, potentially causing injury. So be careful! Also, please make sure that your pewter is lead-free, as the fumes could be very toxic. It is definitely is a good idea to wear a face shield and leather gloves as well.
Pour the molten pewter carefully into the mold and let it cool completely before removing it. Clean the piece with fine steel wool and scrub with soap and water.
Step 5: Metal Finishing
Another safety note: Be very careful with the Pewter Black, as it contains potent acids that can be fatal if misused. Wear protective gloves and eye-wear to avoid injury. This part is probably best to do outdoors if possible. Please check out the warnings on the label.
Place the pewter into a plastic cup and pour the patina onto it. Only a small amount is needed and you will notice it turn black quickly. Remove from the solution, being careful not to get any on your skin and rinse with water. Pat dry with a paper towel and allow to air dry completely. Then, either using the steel wool or a buffing wheel, polish parts of the pewter to expose the shiny metal and leave parts of it black to your personal taste. Looking good!