Casting copper ?

I want to cast some new copper inserts for my copper faced hammers, how can I make a mould from easily available materials for just a one time basic casting?

Bit of tube cut in half and hold together with Jubilee clips would make it easy to get apart.

Now that you mention it I have never ever read or heard about anyone casting copper

All sorts of other stuff yes

Plural ‘inserts’ and one time casting does not equate too well. Better cast in situ, I might think?

You don't say which hammer, but for example a 1&3/4" copper head insert is £6 +vat. Why bother?

You could make them by copper spinning method and fill with molten lead.

I tried this experiment, and found (thanks to a similar question here) that the cast head of the hammer is crimped around the copper insert to hold it in place. Being cast, it's not malleable, so the crimp is a one time event, and the edges of the socket are liable to split if you try and ease them out enough to allow a new insert to be (ahem) inserted.

So I cast lead inserts in situ.

Here's a link to the escapade in question:

Lead faced hammer

Use copper tube for the mould? Becomes part of the end product.

I would push a bar of the correct diameter in some sand and cast as normal. Copper tends to react with oxides so casting into any pipe needs to be done with the pipe very clean, and don't stand over the pipe when casting. Once poured, cover the top of the copper with coal dust, otherwise it "boils". Sand mix:

3% water

10% bentonite (from beauty shop-face mask)

5%coal dust

5%starch (cake flour)

rem sand

With such a simple mould you'll probably get away with 3% water and 10% starch (rem sand)

I'm surprised copper isn't cast more often, a number of the older models had copper chimney stacks...

Casting a new copper head into the old iron holder would work BUT only if the hide face was removed and also the wooden handle. I have never successfully fitted a new copper face - even though you can buy them ! IF you are menting copper start with a handful of charcoal in the crucible as a deoxydiser, then melt as normal, for the mold allow 1/16" for shrinkage on diameter, or heavily rap the pattern before removing from the sand mold. Luker has given a mix for the sand. Good luck. Noel.