I had a really old chess board. It was definitely nothing to write home about. It was poorly made, and barely even in dimension. I should know, I made it when I was in grade 9 in wood shop class at school. It was the first piece of wood work I'd ever done, so it's only expected to be rough.
Apparently, I have never done things normally. The projects are for complete, one piece boards. Yet on mine, I wanted a folding board, and that's what I built. Some of the squares were split and re-glued but not planer enough to even keep the squares flat. I had a border and brass hinges that weren't even straight (the thing folds up at an angle).
I figured it was time for the chess pieces. It's a small board, with squares that were 1", so the pieces all had to be less than 1" in any horizontal position (e.g. 1" diameter or less on the kings base). I managed to find a chess set that was really old (I had a magnetic one as a gift from my dad in middle school), and that was missing a pawn. I first made a test run with that missing pawn, casting it in silicone.
With that done, I set about creating molds for all of the pieces. I went with green and gold, because those were two colors at the time that I loved. I had to repeat a lot of pieces over and over to get the count (I'm not making 8 molds for 8 pawns). I used a Dremel to cut off the bottom sprue from the pieces, and then set it up.
Nice to have that completed.
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