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Hey Dave,
Way to go, you will get there. This is a great start, this isn't an easy deal. I remember doing some sand casting in HS shop and it is a tedious process. I give you a lot of credit.

Nice job working to move vintage forward
Scott

Keep practicing, it will come back. I have a CNC router available to me if that could assist in pattern making. Hal

that might be interesting hal.
i've never done cnc work but i suppose i could adapt.
my only problem with them is they were designed to replace people like me!!!!
i'm old school when it comes to patterns basically make them out of wood and bondo for sand casting.

if i was making alot of molds i'd allow for double shrinkage and cast a master out of metal.
for out purposes here many of the patterns can be made from an actual vintage part.
as aluminum shrinks about 1'4"per 1' the shrinkage is about 1 percent which except certain parts doesn't matter much.

in cases where it effects the use i can easily built up an existing part.
if overall size is really critical i suppose i could even build a electroformer like i did at the jewelery factory.
basically a turbo-charged plating machine.
but right now i am just getting basic tools made and doing a few test casts to get my mind back around the whole thing.

as it is i still need to build a muller,cast a few flasks,hand tools,and a small metal roofed shed so i'm able to cast in bad weather .
i also need to buy some sand for casting over since being a cowboy and casting over moist ground can get some serious hospital time booked.
believe me when i say steam bubble pops are way too exciting and scary.

down the road a bit i have an idea for making die molds from a reversed casting.
it's a bit complicated and i'm not sure anyone has ever done what i have in mind .
first i'll have to build a turee or something like for cast iron.
if i'm right i suppose i'll have invented a new thing ,
anyway heres pix of dude #1 below.
that was a steam bubble defect that almost got exciting.

dave

Interesting David... Thanks for sharing this. As someone who now knows 100% more about sand casting then before I read this post, I have to ask, how (or in what) do you melt the aluminum?

You can always remelt your mistakes and try again.

Rob,
i like to keep my mistakes as a visual reminder that i'm not perfect .
actually it just helps me analize what went wrong down the road a sort of visual note.


Mark,

that's a bigish question.
theres several types of crucibles to melt aluminum.
cast iron , steel tube capped , and the best ceramic.
of course for purity the ceramic is the best option as aluminum mixes with iron or steel and weakens the casting.
everything metal you coat with a wash but for now i'm just going "dirty" while i get my s.o.p. in order.

the actual melt is done in a furnace that is supported by forced air.
the one i built is set up for charcoal or gas.
currently i'm using charcoal as i lack the spare cash for the gas tank .
it's a bit messy but i kinda like it as it's quieter than the gas driven one.

the next furnace we'll be building is a tip furnace powered by gas exclusively.
the current one will then roll into a preheat unit.
the big problem is that i'm currently assembling a space for an entire woodshop that i was given.
i also need to do small repairs and set up my new (to me) metal lathe.

as i'm a self employed single daddy in a recession it is really hard to steal time for these project.
anyway heres a picture of the actual furnace.
it's not pretty but useful things rarely are.

Dave

"not pretty but useful things rarely are."

Hey that's my line!

Hey Dave-
That is way bitchin'!!!!!

I was looking to try it at some point now that I've got the space to try it. There is a great publisher called Lindsay that reprints old tech books and manuals, they have a really cool selection of reasonably priced books on casting geared towards the DIY enthusiast. Check out (http://www.lindsaybks.com/) or better yet, request a catalog, they have some real gems and the printed catalog is a riot.

Dan

i love lindsay publications.
it's a standard Christmas wish list draw for me.
heres possibly the best series of simple technical casting books available stephenchastain.com.
some of his things like flasks are over engineered but he has extensive detail that provides much valuable data.

for simplicity i like Dave Gingery's stuff.
he was a mechanical genius bar none for the diy guys.
simular to when studio glass blowing furnace were developed he created or recreated the ability for a small casting operation to go live for very little money.

anyway i have alot of experience casting and model making.
i figured with these units being built by me i could provide a much needed service for hobby prices.
i already have a few thousand dollars worth of jewelery refining tools gathering dust for 15 years or so.
a couple of burn out kilns vibratory machines metal finishing tools ect. ect.

his machine tool building series is neat but i think he would agree that with the huge surplus of good cheap used units that you'd be foolish to build one today.
i just bought a extremely nice logan bench lathe with a 5" swing for 150.00, it had every tooth angle a 4 tooth chuck spare add ons ect.
ten years ago it would have cost a least a grand.
i also got a combo 46" belt/disk sander for 20.00 this is a nice unit i'd priced at over 300 several years ago,a small part was broken that i had my welder fix for 20.00.
so for under 200 i was able to get a large part of the machinist tools i'll be needing for finish work.

i quit model making mostly because i needed to make a real paycheck and with the Chinese and middle eastern influx of talent that became impossible.
there was also ethic issues since i wouldn't "borrow " other peoples copy-righted work for anyone.
since a great deal of the industry is about "borrowing" i bailed and went to honest work.
Anyway i'm having fun and may be able to help people out when it's all said and done.
something a hobby should be about in my mind.

dave

Thanks for all the info David... I hope you keep us posted on the progress.. I'm sure you'll get it perfected,,, afterall,,,, you're cookin' with Kingsford ! LOL