The Bucket Foundry

[WilDun]

Opps, have I bitten off more the I can chew, this time. This pattern may need some rework bugger it.

This is why the Shell Sand Moulding system for cores is so great. Produces robust high quality finish cores that are are ideal for this kind of fiddly work. But you need a metal die, bugger it. Might have to copy cast the core boxes into aluminium.

Shell sand is good (just like the more flexible crust you would get on a slightly overcooked ginger bread loaf cooked in the oven! ), not so good to eat though!

[Flettner]

I've got it to this point, slide and glue the last section in. This is a good way to see everything is in place, secured and clean before closing up. Im in the process of building up a second one at the moment, might as well have two cock ups I guess.

[Flettner]

No, its become clear that sodium silicate sand is just rubbish when making fine cores, Ive tried every trick. Thought I might get away with it but Ive spent two more days trying to make a second mold, no avail. I've wasted enough time on this. I guess Ill just have to spend more time and make metal dies, @#$/ it, Shell Sand process to the rescue. Arh, so close too.
I just can't imagine this one mold I have on the floor working first time. Always need a few backups. Pour it and see perhaps? I only want one cylinder after all. To be honest I'm a bit over it at this point.

[WilDun]

No, its become clear that sodium silicate sand is just rubbish when making fine cores, Ive tried every trick. Thought I might get away with it but Ive spent two more days trying to make a second mold, no avail. I've wasted enough time on this. I guess Ill just have to spend more time and make metal dies, @#$/ it, Shell Sand process to the rescue. Arh, so close too.
I just can't imagine this one mold I have on the floor working first time. Always need a few backups. Pour it and see perhaps? I only want one cylinder after all. To be honest I'm a bit over it at this point.

That's too bad! - mind you I have seen cores being made out of all sorts of things (even molasses!) - but the fact that you only need Co2 for Sodium Silicate is a very good reason to go that way.
Pity that most of the others seem to require some sort of heat source to 'cook' them!
I know that you don't care much for 3D printers and the lost PLA process, but sometimes that might come in useful for tricky castings!
However, if your shell moulding isn't too far off, - then maybe not!

Would it help to use some sort of finely chopped fibre in your silicate/sand mix which will be easily broken down by the hot metal? - something which won't make the mix impervious to the Co2 of course! - probably not fibreglass because it wouldn't break down so easily, but something like hemp used in gland packing or rope, maybe even cotton wool! (totally shredded of course) - this might give it the temporary cohesion needed for the process - (just a thought).

OR ..... good old NZ flax!

[Flettner]

I have in the past used wire set inside the sand core, even if it breaks it can't fall apart. Just too awkward to get a wire in with this transfer core. I should have known better, its not like it hasn't presented a problem in the past.
The real bastard was I was fitting the last core in place, it fell out taking with it part of another core. Being it was all glued up, too late, had to throw the whole two days work in the bin. But thats how it goes.

[WilDun]

I'm talking relatively finely chopped stuff like common or garden plumbers hemp etc being completely part of the mix. - wouldn't like to see this not going though!

[Pursang]

I'm talking relatively finely chopped stuff like common or garden plumbers hemp etc being completely part of the mix. - wouldn't like to see this not going though!

I believe that Hemp has been used for centuries as a stabilising influence and support, during difficult processes

Cheers, Daryl

[Flettner]

https://m.facebook.com/story.php?sto...00003861602582

https://youtu.be/NoXO2LqlqCs

[Pursang]

[WilDun]

https://m.facebook.com/story.php?sto...00003861602582

https://youtu.be/NoXO2LqlqCs

Your cat? - I think I'm beginning to see why things aren't going so well at the foundry these days!!
( but on the positive side, it may just open a new perspective on pattern making and could release some creative ability you never knew you had!).

[ken seeber]

Well, cast up 4 heads yesterday for the next version of the UHV system. Used CO2, but in a far more basic application than Fletto's very complex mould .
Open faced moulds, placed face down on a preheated steel plate. Poured into the central downsprue. One had a bit of shrinkage in the downsprue, but can't say whether the plate was too hot or too cold. Better keep a record for next time (????). Gave them a preliminary machine, mainly to create a central hole to hang them on to the tree we use for the solution heat treatment of our pistons and brake discs. The small extension to hold the plug boss on centre worked perfectly.

Must say it is, as Fletto said, therapeutic. Sort of a STONED age thing.

[husaberg]

Must say it is, as Fletto said, therapeutic. Sort of a STONED age thing.

primeval responses Ken , who doesn't like setting fire to stuff cooking bbq or clubbing the misses over the head with a club

[ken seeber]

Nah, nothing to do with 2 strokes, nothing to do with casting...

Sometimes you get problems some easy to solve, some hard to solve

and some are just BRAINLESS

[WilDun]

Nah, nothing to do with 2 strokes, nothing to do with casting...

Sometimes you get problems some easy to solve, some hard to solve

and some are just BRAINLESS

Yes, well that one is brainless ok! - his brains have obviously turned to jelly and have come out of his nose!

..... Also easy to solve! (ie by using the proper slicer settings!).

[Flettner]

Cast in LM13.