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Old 02-21-2010, 12:11 PM   #14
Donkey Hotey
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Joined: Aug 2005
Location: 20 Mule Team Trail (Palmdale, Ca)
Oddometer: 12,183
I figured it was one piece, it's aerospace related (his major) and it doesn't have any vertical surfaces to contend with. As aircraft go, that's probably the easiest one to cast out of something. Plus, it isn't something he could easily machine unless he had a CNC (one of his criterion). It's also fairly constant in cross section so shrinkage and cooling problems should be minimal

With a piece of foam and some pictures, you could carve up a plug that would look pretty close and make a casting out of it. It could be hand finished against a belt sander and the flaws would not be so obvious in the final product (it's already kind of a blob shape).

He went for a shot glass instead. At least we know he was PUI when he came up with his final idea.
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