Custom Aluminum Casting

Coral City Foundry

From a serving to casting

After years serving as a Gunnery Sergeant in the United States Marine Corps, I traded my rifle for a crucible. My mission now? To handcraft each USMC chevron with the same discipline, pride, and precision I demanded from my Marines.

Custom Aluminum Casting

Coral City Foundry

From a serving to casting

After years serving as a Gunnery Sergeant in the United States Marine Corps, I traded my rifle for a crucible. My mission now? To handcraft each USMC chevron with the same discipline, pride, and precision I demanded from my Marines.

Coral City Foundry

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Coral City Foundry

The Process

Step 1 Pattern

Design and prepare the chevron pattern with precise dimensions and clean draft angles.

Step 2 Mold

Pack green sand (crushed sand, clay, water) around the pattern; remove to reveal the mold cavity

Step 3 Melt

Charge the crucible and heat the aluminum to pour temperature; skim impurities.

Step 4 Pour

Fill the mold. Let heat and time do their work. Break the mold, reveal the raw casting.

Step 5 Finish

Cut gates, fettle, sand, and polish. Inspect. Only the best earns the right to be worn.

Coral City Foundry

The Process

Step 1 Pattern

Design and prepare the chevron pattern with precise dimensions and clean draft angles.

Step 2 Mold

Pack green sand (crushed sand, clay, water) around the pattern; remove to reveal the mold cavity

Step 3 Melt

Charge the crucible and heat the aluminum to pour temperature; skim impurities.

Step 4 Pour

Fill the mold. Let heat and time do their work. Break the mold, reveal the raw casting.

Step 5 Finish

Cut gates, fettle, sand, and polish. Inspect. Only the best earns the right to be worn.

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