Small sheet of hardboard, any off cuts will do.
A fretsaw (hand or powered)
Leadfree pewter, which you can buy online.
Blowtorch, or small camping stove.
A clip for the hairslide or a piece of dowel about pencil sized.
Solder and soldering iron or pencil torch.
Polishing wheel or dremmel.
Step 2: Making the Hardboard Mould
Place the first board onto the next board and draw around the oval shape, next draw the waves within this oval shape onto the board, cut the waves out with the fretsaw and lightly sandpaper. Thin down the waves with sandpaper so that they are about 2mm thick, use wood glue to attach the wave shapes to a piece of board as in the photo. So what you have is a three part mould, an oval shape that drops over the wave shape and then a flat back. Cut a v shape in the top of the oval as in the photo and file a groove in the back board with a round file, this is for pouring pewter into when the mould is put together. Make sure the smooth side of the Hardboard face each other not the rough side.
Step 3: Put Mould Together
So we are ready for the casting.
Step 4: Casting
I use a blowlamp to melt leadfree pewter in an old tarnished spoon (low tech) the pewter doesnt stick to the spoon and it pours small amounts well. You can melt using a small camping stove which should melt the pewter in less than a minute.
When the Pewter is liquid, pour slowly into the slot in the top of the mould, be ready for metal that will run out from the top when its full and also trapped air can cause hot metal to blow back. (wear the goggles and gloves, and or a face mask.)
Step 5: Let Cool & Open the Mould
I use a polishing mop in a drill stand and start with coarse paiste and work through to fine, then I give a final polish with silver polish (brasso) You can use a dremmel type tool with a polishing head or wet & dry paper working to a fine grit and then go to silver polish.
Step 6: Solder on the Clip
To solder the clip I use leadfree solder on the back of the clip and then I place the front of the hairslide onto a damp sponge or rag.
I then place the clip on the back of the hairslide and sweat solder the clip in place, the damp rag stops the heat from soldering burning through to the front.
Give everything another clean up and your done. This method of casting pewter can be used for lots of simple designs with no undercuts. Once you get more undercuts you need to cast into silicone moulds. The Hardboard should last for quite a few castings and hold up well to the heat, but it will burn if you catch it with the torch.
Safety first, make sure to wear gloves and goggles and be aware that pewter will burn, please dont send me pics of horrible burns or a hole where your house used to be! If your not sure of something stop and have a read up on it and then start again. Its my first go at an instructable so go easy on me, Im happy to answer questions and alter the make where needed. Have fun.