How I make my mini aluminum snowmen.

ripjack13

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ok, so I'm still no expert at this, but this is my set up, and this is way I made a few of them, and this way seems to work the best for me.
YMMV

These little guys are all scraps from aluminum rod cut offs I got at work. The bodies are no taller than an inch and a quarter. Add in the hats and they can be about 3 inches tall. I try to make each one a little different.
Sanding them with successive grit sandpaper is important, if you don't and miss a grit, when you shine them up the little scratches will stick out like a sore thumb. (DAMHIKT)
The starting grit is up to your turning skills, how smooth of a cut when you're done shaping is the determining factor, after that I just go up to 12000 and then use a product called "One Step Plastic Polish" that I get from PennState Turning or amazon
After it's polished, I use some good ol renaissance wax to shine it up nice.

Roughing out the blank I use a rounded diamond shaped carbide, and then a pointed diamond carbide to get the body crease nice n sharp looking.

Ok....with all that said, let's move onto the picture show....
 
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First I have to get in the spirit of making snowmen....

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first up is the aluminum rod blank....

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mounted in lathe...

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Then, get your @woodtickgreg tools diamond shaped tool. The rounded tip is great for this.

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Start by lightly taking off material that doesn't look like a snowman....

I can not stress enough,

DO THIS VERY LIGHTLY!

It will take longer to do it, but longer is better, because you won't break your tip or dig in too far too fast and have the piece fly out at yer dome.



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here's how big I'm aiming to make em.

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Here it is almost to shape. You can use the sharp diamond tipped tool to do the crease where the head meets the body if you want a nice crisp seam, but otherwise the rounded tip will look just as good.

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I start sanding with 150 grit and move all the way up to 12000 micro grit.

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when your using the micro mesh, beware, the aluminum will turn everything you touch, black. so if you're partial to using one set of micro mesh for this, keep it separate from the others that you use for other turnings.
I have one dedicated set I use just for aluminum and steel projects.

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once I'm happy with the sanding of it, I'll follow up with some one step polish and then renaissance wax.

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Then I use a hacksaw blade and cut em off without the motor on. being very carful not to touch the body and scratch it up.

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Then sand the bottom of the body on a piece of sandpaper stuck to a board so you have a nice flat spot there.


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Where the live center was stuck on the head side is where I drill a small spot so the glue for the hat has something to catch on and stay stuck.
Or you can make the hat and body all one piece. But I like the looks of contrasting materials. So it looks like this when it's finished....

IMG_20251126_161430_MP.webp

I'll see if I can upload a video of the process later.
 
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@trc65 here ya go my man. It took a lil while to get posted. Sorry bout being late.
 
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Sorry about the sound. It gets loud....
Here's some vids of the process....
2 shorts, and 2 longs. Idk why they separate them like that. But there's 4 total videos.




 
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Sorry about the sound. It gets loud....
Here's some vids of the process....
@ shorts, and 2 longs. Idk why they separate them like that. But there's 4 total videos.




Great tutorial!
 
Appreciate you documenting this. I know I've got aluminum scrap sitting around so will be giving this a go. I don't use any carbide tools so I'll be playing to see what I can do with gouges. I've done brass with gouges as well as resin/acrylic so will see how I do. Thanks for the tip on sanding (black), I knew this, but probably wouldn't have registered until after the fact.

The other metal work I want to try is casting and turning some pewter. It's softness and low melting point (<450°) make it easy to work with.

A little over a year ago a friend of my mom's died and we inadvertantly ended up with pounds of her tea/coffee service and other pieces of pewter. Mom doesn't want it, and we've tried selling and giving it away and nobody wants it. Figure I might as well put it to use.
 
Appreciate you documenting this. I know I've got aluminum scrap sitting around so will be giving this a go. I don't use any carbide tools so I'll be playing to see what I can do with gouges. I've done brass with gouges as well as resin/acrylic so will see how I do. Thanks for the tip on sanding (black), I knew this, but probably wouldn't have registered until after the fact.

The other metal work I want to try is casting and turning some pewter. It's softness and low melting point (<450°) make it easy to work with.

A little over a year ago a friend of my mom's died and we inadvertantly ended up with pounds of her tea/coffee service and other pieces of pewter. Mom doesn't want it, and we've tried selling and giving it away and nobody wants it. Figure I might as well put it to use.
Secondary use for pewter , if it isn't lead based, is to coat copper pot interiors to keep from poisoning yourself with the copper.
 
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