A Complete Story of Hammer Making

This video details the process we completed in order to cast a hammer from aluminum, from making the kiln through making our own foundry tools, testing, and finally pouring in our handmade cast. The product would be a hammer that would not produce sparks if dropped on concrete, but the goal of the project was to learn how to cast metal. We worked on evenings and weekends during the month of October with help from several makery members and in the end we made a pretty good hammer. If you would like to see the beautiful shiny hammer live in person and grip it by the finely-detailed handle, just come on by Omaha Maker Group whenever you see the “open” sign indicated here on the web site. We also have meetings on Tuesday nights.

Casting Aluminum

OMG has had a kiln made of high quality refractory brick for a while now but recently Kevin led an effort to rekindle it. After a couple weeks of preparation we spent Saturday morning making last minute adjustments and then fired it up. In all, it only took a half hour or so to turn a bucket of scrap aluminum into ingots of metal, ready for casting. Several members stopped by to watch and help out. The weather was perfect and the procedure went smoothly – hopefully this is the first of many times the kiln will be used, now that we have streamlined the process and assembled all the necessary tools.
Here’s a link to a quick edit of video footage from a camera stationed on the dock behind OMG. A more complete video of the process is forthcoming.

What’s inside an integrated chip?

I damaged a CD4093BE and instead of throwing it away I decided to satisfy my curiosity regarding its guts. I used Omaha Maker Group’s belt sander to grind away the top layer of material and it revealed a tiny chip embedded within. The slightly orangey color on the right side is where I sanded away a little too much of the tin protecting the copper legs. In the closeup view, you can just make out where filamentous wires must connect the legs to the chip.

Preparing to apply the IC to a belt sander

4093 integrated circuit beneath the covers