I decided to get the pattern for the lead keel bulb 3D printed, this would save me time trying to make it. It was too large to print in one section so I glued the two sections together and stuck them onto an offcut of ply.
I then made a wooden box and fixed the pattern into position and filled the box with cement, when I came back the next day I removed the pattern and was left with a nice mould ready to cast the lead.
I cut up an old gas bottle and made a stand that would allow me to safely pour the lead into the mould.
I was luck enough to be given over 120Kg of scrap lead from friends and even friend of friends that I did not even know. Thanks to everybody who donated the scrap lead.
I had some help to pour the lead and the first attempt went well, the only problem was that towards the end of the pour the last 5Kg of lead set around the top of the gas bottle so I was left with a bulb that was only 65Kg. I decided a large gas blow torch would help as this would allow me to heat up the top of the gas bottle before I started to pour and hopefully allow all the lead to pour out in time.
I borrowed a blow torch and with the help of some good friends had another go, this time all the lead poured out and I now have two nice lead bulbs for either side of the keel plate.
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