Need some ideas on duplicating small metal pieces

[jtluttrell]

I wanted to see what the minds here could come up with. Any help is appreciated.

I would really like to duplicate these keyhole covers. I have 4 and need 4 more. They are about 1-1/4 square and .03" thick. Aside from the outside shape, the interior design is embossed or engraved.

I had some ideas, but I tend to over complicate things. :-)


http://i571.photobucket.com/albums/ss154/warchild84/IMG_20140828_104409_805-1_zpsacakxht0.jpg

[Ted S.]

Are there any machine shops in your area? They may be able to machine one that is almost a facsimile of the original if the machinist is good enough. Don't know how much something like that would cost though.

[DaveTN]

I’d cut about a 2” thick stack out on a wire EDM machine and either take them to an engraver or engrave an electrode and burn the engraved detail on a sinker EDM.

I tend to over complicate things also.

[TrickyNicky]

My advice? Whatever its on try to find another on eBay to scavenge parts off of. Now without knowing more details I don't know how feasible that is, but if it was anything even semi-mass produced that might be your best bet.

Also just try searching for keyhole plates/covers/whatever, you'll likely get 10 billion hits to search from, but an hour of going through them while watching TV might just get you where you need to be.

[Omega]

Try casting your own; its not that difficult.
http://www.webcomsknkwrks.com/castbook.htm

[peejman]

I'd look into scavenging as Nicky says, or maybe find a shop that can make an embossing tool from the original. That probably will be quite expensive for 4 pieces, however.

[Trekbike]

If it's just decorative, you can get with a company that does 3D laser scanning and then 3D printed. Not cheap though. Sent from my SCH-I545 using Tapatalk

[jtluttrell]

That was fast! 

 

I've googled this to death already looking for old ones. I don't think this was a production piece so they may be one of a kind. There is a place in town that collects this kinda stuff I may check out, but the odds of finding 4 alike......

 

I think casting is probably going to be my most practical solution. It would be a handy thing to know in the future too! Thanks for the link, Omega. Lot of good info here. I knew I could count on you guys.   :up:

[RED333]

Yep, I would cast them, find ya some zinc.

[Omega]

Yep, I would cast them, find ya some zinc.

yup, good use for those pesky zinc wheel weights.

[Guest kingarmory]

Yup, casting will be your most economical option.  Machining would require a few hours of setup and you'd also need a CAD/CAM file (blueprint) for it.  If you were making 500 of them I'd help ya out.

[Two Dogs]

http://www.vandykes.com/m/

You could try Van Dykes.

[enfield]

Laser scanner and 3D printer.

 

Or:

 

use one as a pattern and make more with investment casting.

 

Both ways would be expensive, but it depends on how badly you want them.

[tnguy]

If they don't have to be metal, you could try this

 

 

Pretty easy to use.

 

Casting metal would be a little more work but may be worth it.

Edited September 10, 2014 by tnguy