jungle_jim01
Member
- Messages
- 189
- Location
- Loftus, North Yorkshire
I've received a lot of useful advice from this forum lately, Thanks to everyone, so thought i'd share this incase anyone else finds it useful.
The sash window's made and ready to go in was just about to click the buy button for some sash weights (at a not so cheap £70) when i had a cunning plan! (am i painting a picture here!)...as a child i used to make my own fishing weights using scrap led that my dad had knocking around. Conveniently we're in the middle of re-roofing our house and have a couple of sheets of heavy duty led from the old valleys. Having successfully made my sash weights and saving a small fortune i thought i'd share this incase it's of use to anyone else.
At this point the Health & Safety beast needs to come out so here's a few words of caution...
1. water and molten led doesn't mix in any way (quite explosive as the water boils instantly in the led!)
2. Led Fumes are Very Toxic, make sure you're outside or a very well ventilated space anyone trying this should take care.
3. Fire and Molten Led is very hot!!
(that's my back covered now!)
Making Sash Weights
1. Decide on shape and size weights need to be. (due to the design of the window i was slightly restricted in size and so decided to make several weights for each cord in a stacking configuration. This means that it's possible to access the weights and remove through the a slot in the frame if needed.
2. Make a mold: I used 2 pieces of wood, clamped together and a 32mm drill to bore a hole through the middle. The result is a two part mold which splits easily.
3. Melt Led: An old tin should do the trick and my garden chiminea was more than hot enough. (CAUTION: Led fumes are very toxic)
View attachment 2
4. Setup the mold: while everything's cooking get the mold set up. Insert a bolt down the centre and clamp together tightly. (i used a size 8 Bolt and drilled slightly deeper in the centre for it to sit securely. Also worth steadying the mold with some bricks.
5. Remove Slag: There will be a lot of impurities which float on the surface: remove using an old spoon and long pliers.
View attachment 1
6. Pouring Led: Very Very Carefully remove the cooking pot and pour the molted led into the mold)
7. Leave the led to cool for a couple of minutes
continued below...
The sash window's made and ready to go in was just about to click the buy button for some sash weights (at a not so cheap £70) when i had a cunning plan! (am i painting a picture here!)...as a child i used to make my own fishing weights using scrap led that my dad had knocking around. Conveniently we're in the middle of re-roofing our house and have a couple of sheets of heavy duty led from the old valleys. Having successfully made my sash weights and saving a small fortune i thought i'd share this incase it's of use to anyone else.
At this point the Health & Safety beast needs to come out so here's a few words of caution...
1. water and molten led doesn't mix in any way (quite explosive as the water boils instantly in the led!)
2. Led Fumes are Very Toxic, make sure you're outside or a very well ventilated space anyone trying this should take care.
3. Fire and Molten Led is very hot!!
(that's my back covered now!)
Making Sash Weights
1. Decide on shape and size weights need to be. (due to the design of the window i was slightly restricted in size and so decided to make several weights for each cord in a stacking configuration. This means that it's possible to access the weights and remove through the a slot in the frame if needed.
2. Make a mold: I used 2 pieces of wood, clamped together and a 32mm drill to bore a hole through the middle. The result is a two part mold which splits easily.
3. Melt Led: An old tin should do the trick and my garden chiminea was more than hot enough. (CAUTION: Led fumes are very toxic)
View attachment 2
4. Setup the mold: while everything's cooking get the mold set up. Insert a bolt down the centre and clamp together tightly. (i used a size 8 Bolt and drilled slightly deeper in the centre for it to sit securely. Also worth steadying the mold with some bricks.
5. Remove Slag: There will be a lot of impurities which float on the surface: remove using an old spoon and long pliers.
View attachment 1
6. Pouring Led: Very Very Carefully remove the cooking pot and pour the molted led into the mold)
7. Leave the led to cool for a couple of minutes
continued below...
