On Wed, 05 Sep 2007 15:19:32 -0500, F. George McDuffee
wrote:

For a one off consider lost foam casting. You make up the part
in styrafoam or urathane foam, and the runners, pack sand around
it, vent with wire or soda straws and pour in the metal. The
foam flashes and burns out. You can coat the foam with a
refactory for an even better finish.
========
If lost foam sounds like a possibility for more info click on
http://www.lostfoam.com/assets/conte...e_castings.pdf

http://www.thomasnet.com/products/ca...2280228-1.html
http://www.sculpture.net/community/s...ead.php?t=4880
http://ezinearticles.com/?Sand-Mould...ting&id=332403
http://ezinearticles.com/?Lost-Wax-a...sses.&id=85804

One thing to remember if you try lost foam is that clouds of
black smoke are generated. Both urethane foam and styrofoam
smoke are toxic and you must not breath it. Not a good idea to
be choking and half blind and trying to control/pour molten iron
or aluminum...

Good luck and let us know how you make out.
Unka' George [George McDuffee]
============
Merchants have no country.
The mere spot they stand on
does not constitute so strong an attachment
as that from which they draw their gains.

Thomas Jefferson (1743-1826),
U.S. president. Letter, 17 March 1814.