Does Anyone Cast Their Own Patch Boxes

[Norman Brooks]

Just want to know how it was done using todays materials and not a manufacturing process.

 

[rich pierce]

I’ve never cast one but have been made them with flat sheet brass.

 

[SOLANCO]

I can not say they were never cast, but do not see why they would be. Casting that thin would be finicky work compared to trigger guards and butt plates. And I wonder how well a thin casting would stand up.

 

[Robby]

I do not cast them myself but this one is made from a casting made for a right hand Lehigh. I had to braze on a bit to the lid to make it work.

It is my understanding that most were castings. Years ago Dixie Gun used to offer patch box castings, some very intricate.
Robby

 

[dave_person]

Hi,
Some early patch boxes were cast. For example at least one Christian Oerter rifle has a cast box. Most were made from sheet metal. I suspect some later cap boxes might have been cast. I don't cast patch boxes but I do cast a lot of other parts such as side plates and escutcheons. Your best and cheapest bet is to use Petrobond Sand to create the mold. Your cope and drag can be simple and made of wood. You need a good way to melt the brass or silver, which can be done with a gas welding torch but for something the size of a patch box, a crucible in a forge or high temperature oven is likely needed. Here is an example where I cast a large handle to be used on a historically correct British pistol case.

dave

 

[Norman Brooks]

The reason I asked is I used electrical motor contacts which is suppose to be 25-50% silver. Use the Petrobond sand but had problems with it falling apart. I still have lots left to make other things with. It did turn out good. Just a pain to try to cast. Nice gun Robby and nice box dave_person.

 

[dave_person]

Nice cap box, Norman! If you had trouble with Petrobond, you might try Delft clay. It is more expensive but the binder is very good and it holds the mold really well.

dave

 

[Whitworth]

The reason I asked is I used electrical motor contacts which is suppose to be 25-50% silver. Use the Petrobond sand but had problems with it falling apart. I still have lots left to make other things with. It did turn out good. Just a pain to try to cast. Nice gun Robby and nice box dave_person.

Nice work.

 

[Dude]

We've got some real artists here! Wow - I'm impressed!

 

[dave_person]

Hi,
Here are images of casting the hooks for the pistol case and a few more examples of what can be done at home. In these photos I am using Delft clay to make the molds. Petrobond is cheaper but Delft clay is stickier. Norman, with Petrobond, you really have to pound it into the cope and drag a bit more like old sand molding.

You are only limited by your imagination.

dave

 

[Norman Brooks]

That is some really nice work, and so intricate. I have a long ways to go to get to that point. I'll have to remember Delft clay...

 

[Pete G]

There are lots of examples of cast boxes on early rifles.
Perhaps the technology for sheet metal was not available yet ?

 

[dave_person]

Hi Pete,
I believe they often cast brass and then beat it into sheet with planishing hammers.

dave