How to Make a 25 Pound Ball of Aluminum Into a Trophy

In June I was approached by a local aluminum manufacturing company to make a trophy for their annual softball tournament. Without giving any specifics I agree. A few days later he brought in a 25 pound ball of their aluminum. This is what he wanted me to use as the top of the trophy. He didn't want anything painted. I decided the only thing I could do would be sandblasting.

Managing the Heavy Ball

First, a hole was bored into the bottom of the 25 lb, 7.5" diameter ball. I used a ratchet socket to create distance when mounted to a board. It was much easier to manage.

Preliminary Test

Not knowing what sandblasting would do to the aluminum, I tested a flat piece. Since I wanted the softball to be white and the image darker, I reversed the stencil.

Mocking Up a Sample

I created a 7.5" softball in a drawing program and use a vinyl cutter to make a pattern of the "skin" and applied it to the ball. This was my guide for the placement of the stitching and logo.

Preparing for the Mask

I used very thin tape to position the stitching line before removing the pink template. I used the vinyl cutter to cut the mask for the logo and the stitching. The mask was a 7 mil. vinyl.

Apply the Mask

I applied the vinyl cut mask for the stitching first, followed by the front and back logos.

Sandblasting

The aluminum was white and sparkly after sandblasting. I used extra fine sandblasting abrasive.

Mask Removed

Here is the ball after the mask was removed. I rinsed, dried and sprayed the ball with a clear coat. Just needs the base.

Finished

I used a premade base and added a black spacer for the ball to rest on. I also mounted the metal laser engraved, plate to the front of the black spacer.
Finished 25 pound solid aluminum softball trophy!
The customer absolutely loved it!