Casting & Turning a Hybrid Blank Pizza Cutter

May 21, 2024

In this project, Mike Nish crafts a unique hybrid blank by combining the natural beauty of stabilized Maple Burl with Alumilite casting resin.

He begins by preparing the stabilized Maple Burl cap, ensuring it is clean and free of debris. Mike adds mica pigment to the burl, then measures the Alumilite casting resin in a 1:1 ratio by weight. To add a personal touch, he adds a dye to the resin mixture and shows how to create swirls and patterns that will be revealed once the resin cures.

Mike demonstrates proper mixing technique to avoid air bubbles that can mar the clarity of the finished piece. He slowly and deliberately stirs the resin, ensuring a uniform distribution of dye and hardener. He then pours the resin over the Maple Burl cap, allowing it to flow and self-level, creating a seamless bond between the two materials.

To ensure the blank is as clear as possible, Nish places the blank in a pressure pot, which helps to eliminate any remaining air bubbles and ensures a crystal-clear finish. After the resin has fully cured, he removes the blank from the mold, revealing the stunning combination of natural wood and vibrant resin.

Mike then moves on to turning a pizza cutter handle from the hybrid blank. As he turns, the intricate patterns of the Maple Burl and the vibrant colors of the resin are slowly revealed. He shares his turning advice, explains what tools he uses and why, and talks through each step of the turning process.

He also gives his tips for proper sanding and applying a CA finish, then shows how to polish the blank to a glass-like shine that highlights the beauty of the materials.

The finished pizza cutter handle showcases the unique possibilities of combining wood and resin. Mike's detailed instructions and clear demonstrations make this project accessible to both experienced woodworkers and those new to the craft.