some new props

Yep, now offering a 36" pipe wrench, a 12" crescent wrench, and a golf club.

Not too much new in the world here.

Working on a few props, including a 32" cannon that I'll probably detail the build here as it comes together. The barrel, I'm sure that there is a different term for it that I don't know, will be shaped out of XPS foam sheet. That's already been epoxied together with a threaded rod fit down the center. It will be mounted through the headstock of a lathe on an extension fit behind it and the far end of the rod will sit in a bearing. As with all foam, a rasp, file card, and dry wall screen will be used to shape it, all while the lathe runs in reverse to keep the speed down which should help prevent the foam from melting and tearing.

After the barrel is shaped, I'll coat it with wood glue to seal the foam, one or two coats is usually enough. Bondo "cut" with polyester resin will be applied, allowed to cure, then sanded and filed on the lathe. Finally, some spot putty to clean that up and make a nice glassy surface. Follow that up with some filler primer and we're ready to move on.

This is a private commission for display, but a mold will be made for casting fiberglass copies. Eventually I plan to make one that will fire pneumatically, perhaps marshmallows or NERF balls. I'm going to be making at least a 2 part brush-on 50 and fiberglass support shell. The plan is to only shape the last few inches of the barrel, then on casting to fit some PVC pipe into it.

To make the castings, both halves of the mold will have fiberglass matte laid up by hand, being careful not to cross the edge of the mold. When that has set, a bondo/polyester resin mix will be made, fiberglass tape applied to the seams, and the mold will be closed. I'll rotate the mold so the mixture bonds the two halves together. On opening the mold some final work will be needed, as is always the case, but this is mostly light sanding and touching up the seam with bondo, or spot putty, or both. The casting will be primed, then painted to look like either brass or cast iron.

The carriage will be another story.

For the immediate future I'll simply detail the cannon's construction.

Stay tuned for more on that....

...but first, Bucky Katt needs to get off my bench.