Because I do some hobby blacksmithing, I just use my own - it isn’t ideal, but it’ll get the job done. There are countless tutorials online on how to do this, and you can invest as much or as little time and money as you prefer. To heat and melt the brass enough to pour into the knuckle duster mold, you’ll need some kind of refractory to get the temperatures high enough. Be very careful not to crack or break the plaster. When you are sure the plaster is dry, you can carefully embed the plastered foam knuckles into the top of the sand, still leaving the top exposed. Buying those products is not necessary for the sake of this project. If you do some internet sleuthing on metal casting, you will find recommendations for products like professional casting sand and tutorials on how to make your own casting sand. You will need a container wide and deep enough to hold your Styrofoam knuckles and at least three inches of sand in every direction. Let the plaster of Paris dry completely overnight or until you are sure there is no moisture left.Īs the plaster is drying, you can prep the next steps. Any exposed foam should be covered with ¼ to ½ inch of plaster. Place the foam knuckle duster on a piece of aluminum foil with the most aesthetically pleasing surface facing up, and cover any exposed foam thoroughly with the plaster. Any lumps or inconsistencies could be a headache later on. Plaster of Paris, which can be found in most art sections of department stores, should be thoroughly mixed to a consistency slightly more runny than peanut butter. Careful preparation will reduce the risk of heating and pouring molten metal. I also suggest reading this article all the way through before starting, making note of any materials you will need to acquire. Double-check that the cut-out template fits your hand, and make any modifications that may be necessary for a comfortable grip. This template will be used as a stencil for the following steps. When you are satisfied with the design, carefully cut the design from the paper, including all of the finger holes. The design I am using is modeled after the UK military-issued brass knuckles circa WWII. If you are artistically challenged, there is a plethora of brass knuckle outlines on the world wide web that you can use for inspiration or copy-paste-print. Just sketch out a brass knuckle duster design approximately the same size as you would have the finished project be. Use a note card or the cardboard from a cereal box or case of beer. To get started, you will want to flesh out a design on paper, or better yet, cardstock. Now there's a reason to hold onto that spent.
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