I agree that the least of our work would be the melting and pouring of the silver. I guess what I am getting at is, what is the best way to get the mold. I have seen 2 profesional ways of doing it in my research. sand casting and investment casting.
 
http://en.wikipedia.org/wiki/Sand_casting
http://en.wikipedia.org/wiki/Investment_casting
 
I just wasnt sure which way, if not an alternative to these ways you had in mind.

this is what i think would be easiest.
http://thelibraryofmanufacturing.com/expanded_polystyrene_casting.html

I went to the Strum-Ruger factory and saw the sand casting method they use to produce their weapons. Very interesting stuff, but I don't think it would be advisable. Working with molten metal it very dangerous, and I have read too many horror stories about peoples crucibles exploding from improper procedures. No one here needs to get maimed in the name of computing.

Milling is the safest way to go. Plus I would hate to see ruined product. I looked into this process to recover all the copper I mill away, just not worth it to smelt it back into a usable form. Plus all the impurities that would contaminate the metal could change the molecular composition from Cu110 to something else.

I don't mean to discourage anyone from trying new things (lord knows I try everything) but playing with fire, it the same house as my kids doesn't sit well with me. If I had someone experienced with it guiding me, I would certainly do it, but lots of time, effort and money to build a proper furnace in the backyard.

nateman_doo

I went to the Strum-Ruger factory and saw the sand casting method they use to produce their weapons. Very interesting stuff, but I don't think it would be advisable. Working with molten metal it very dangerous, and I have read too many horror stories about peoples crucibles exploding from improper procedures. No one here needs to get maimed in the name of computing.

Milling is the safest way to go. Plus I would hate to see ruined product. I looked into this process to recover all the copper I mill away, just not worth it to smelt it back into a usable form. Plus all the impurities that would contaminate the metal could change the molecular composition from Cu110 to something else.

I don't mean to discourage anyone from trying new things (lord knows I try everything) but playing with fire, it the same house as my kids doesn't sit well with me. If I had someone experienced with it guiding me, I would certainly do it, but lots of time, effort and money to build a proper furnace in the backyard.

Words of caution should always be received well as they show that a person cares for the continued good health of those around them. I take the point well. the website shows other forms of casting metals, and this wouldn't at least for me be the first time I've done such things. I used to make Christmas Tree ornaments with my grandmother many years ago so I am familiar with  the processes. However when I did it in the past we did not use the system that seams to be Gratuitous's pick. The website he provided though does show the method my grandmother and I had used. Which brings me back to the clay mold's i had mentioned earlier. I never experienced anything where the mold exploded, however there was danger in the pouring process if the metal was to come in contact with skin. If either of you are wary of performing the pouring process I would be willing to do this my self. Though I would request a copy of the finished product milled from some material i could use to press into the clay to give the desired shapes. Then if there were any issues where there was extraneous materials once the cooling process had finished i would send the item to either of you to mill out the imperfections. Let me know if we wish to continue with this plan or if you feel you wish to continue with the foam evaporation method you have shown Gratuitous. Either way will be fine for me as now that I've already spoken with my wife about it and gotten the almighty approval to buy the silver for it I would like to continue in one manner or another this could remove the danger of one of you harming your selves. :)
Ceramic method
http://thelibraryofmanufa...amic_mold_casting.html

awesome

So I know, its been forever since I did anything with this project. I have been very busy away from it trying to pay the man, if you know what I mean
 
anyway, I have some new hardware: 2- x5672 processors, a second sr-2 for another project, 3 more rads, a dual pump top, (3 pumps total) and 2 560ti classy gpu's along with about $500 in quick disconects and fittings. will be custom wiring the psu's with quick disconects so the mb tray can be removed on the sliders in 15 seconds or so.
 
stay tuned for some work on this. I have decided to ditch the tec idea and go to a closed 4 rad system internal regulary cooled with a heat exchanger and valve system to allow external chilled water to bypass the rads when summer comes. I picked up 2 3000 btu window a/c units to play with a setup.
 
should be interesting.

My god how much is this costing ya?  Sounds like a great project.  I can't wait for finalized pictures!

I'm inspired to try my hand at a bandsaw.  Haven't touched one since highschool a decade and a half ago.  Wish me luck.  Going to get some bandaids.

WOW!!!! just wow!!!!

ooo pretty !! :)
 
and i bet you could sell the MDF prototype for a bit of return :)

what about an ebony black epoxy hand rubbed finish for tthe wood prototype?
 
or send it my way and i can do a hand rubbed linseed oil one ;) make it smooth as a baby's butt :)

No worries there can be markets for the most obscure things you may ever think of. chiapet and pet rock two very big prime examples so all it takes is showing the right people what you build :)

Looking pretty awesome, and the custom copper pieces make it even better. Nice project!

I'm a little jealous, just a little

Thats going to be a beautiful monster. Thats the only way I could think of describing it. The power available is the monster and the design and overall appeal is the beauty. Can't wait to see it done.