For the sand mould I used a plastic star pattern and oil bonded sand to create the sand mould.
All the homemade foundry and foundry equipment that I used is D.I.Y.
Using this type of pattern is very easy to sand mould, one disadvantage is its not a split pattern so the sand mould process takes a bit longer.
All that you need to start is to construct the foundry flask to hold the sand and either use foundry green sand or foundry oil bonded sand, and of course to construct a foundry ;-)...
So in the next set of images you can see the sand mould preparation process before and after removing the star pattern.
Well the casting turned out very well so all that was left to do is clean all the access aluminum and give the aluminum star a semi polish finish.