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Thread: The Bucket Foundry

  1. #4861
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    22nd November 2013 - 16:32
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    You've gotta admire them, for so many reasons.

    Makes one feel like an absolute woose wearing shoes when casting

    One main issue doing this stuff, is losing the shrinkage allowance. Say the cover was 350 mm long, using a 1% allowance for aluminium, it would be 3.5 mm shorter. Definitely an issue.
    "Success is the ability to go from one failure to another with no loss of enthusiasm.

  2. #4862
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    Quote Originally Posted by ken seeber View Post
    You've gotta admire them, for so many reasons.

    Makes one feel like an absolute woose wearing shoes when casting

    One main issue doing this stuff, is losing the shrinkage allowance. Say the cover was 350 mm long, using a 1% allowance for aluminium, it would be 3.5 mm shorter. Definitely an issue.
    Depends if the main case it's going on has been cast using the same method.....

  3. #4863
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    22nd November 2013 - 16:32
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    Correct Greg, but if you have fixed dimensions for, say crank & gear centres, then it would be an issue.

    On the other hand, it could be a way to make miniature models, just do this 20 times.....
    "Success is the ability to go from one failure to another with no loss of enthusiasm.

  4. #4864
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    Quote Originally Posted by ken seeber View Post
    You've gotta admire them, for so many reasons.

    Makes one feel like an absolute woose wearing shoes when casting

    One main issue doing this stuff, is losing the shrinkage allowance. Say the cover was 350 mm long, using a 1% allowance for aluminium, it would be 3.5 mm shorter. Definitely an issue.
    Quote Originally Posted by Grumph View Post
    Depends if the main case it's going on has been cast using the same method.....
    or you just wiggle the pattern...............
    Quote Originally Posted by Katman View Post
    I reminder distinctly .




    Kinky is using a feather. Perverted is using the whole chicken

  5. #4865
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    Quote Originally Posted by husaberg View Post
    or you just wiggle the pattern...............
    No-one minds the odd wiggle Hooser, but that's a fair old wiggle...
    "Success is the ability to go from one failure to another with no loss of enthusiasm.

  6. #4866
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    Paint the pattern with really thick paint?

  7. #4867
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    Quote Originally Posted by Flettner View Post
    Paint the pattern with really thick paint?
    Maybe some fine beads
    Quote Originally Posted by Katman View Post
    I reminder distinctly .




    Kinky is using a feather. Perverted is using the whole chicken

  8. #4868
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    9th September 2013 - 06:34
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    New 50cc iron jug done for this year.



    First one was otherwise good but of course failed to core blowholes in the most critical part. I tried to fill them using cast iron as filler but that failed miserably, turned hard as a crystal.



    Second one I improved cores by using sodium silicate for center core and making a bigger hole inside it. Other cores used about 2.8% of epoxy (net ratio maybe a bit over 2% after mixing losses). Epoxy cores work fantastically, they just fall out after casting. Sodium silicate core have to drill and hammer out. On top of that, it is hard to control the CO2 gassing. If gassed too much they will become extremely brittle.

    Still two pores but this time much smaller and luckily avoids critical spots. I think these defects may be something other than core gas, maybe entrainment defects (bifilm). Could be fixed by improving gating system but hard to say how.









    For the first one I melted again half of a Singer sewing machine. For the second one I used gating parts from previous melts, a little bit of Singer and some dirty scrap iron from barbeque oven plates. I had a belief that the sewing machine iron is much higher quality and will provide good machinability which the first cylinder was, so I wanted to spare the sewing machine iron and at the same time test if iron quality will suffer from remelt and low quality scrap. It didn't, machined just about as well but actually there was one small spot where it was harder.

    Core assembly. It took around 5 months to design and 3D print the core boxes. After that only 2 hours to make and assemble cores not including glue drying time. Ramming up the mold takes about 1 hour. Soon can start mass production (not)


  9. #4869
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    Very nice effort
    I've had to clean up a couple of old Singer tables for my wife to repurpose.....i don't know what she's done with the machine bodies.
    They're certainly nicely cast so probably a good quality decorative casting iron.

    I think I'd probably have used a cut up engine block for iron closer to the correct specs but it may not make much difference.

    For filling voids I'd use bronze welding. I've actually got the correct flux here for bronze welding cast iron. It's readily available.

  10. #4870
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    So I looked on EvilBay. Jeez they really aren't worth much are they? I guess they were so ubiquitous.

    Maybe in another 40 years. Oh. Right.
    I've been told. Dreaming`s free.
    Think I'll go, back to sleep.
    Everybody listen, voices in my head
    Everybody listen, do yours say, what mine says?

  11. #4871
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    Those old sewing machines seem to be those type of things that at first glance make people think "oh it must be valuable" but actually they are completely worthless. It probably is that millions of them were made back in the day. I found this one from a metal recycling place for free

    I have to try melting brake discs. They are a good source but I have heard that they may be a bit "harder" cast iron, thus the end product may not be as good to machine. Cannot know for sure until tried.

  12. #4872
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    Boring............
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  13. #4873
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    Home casting at work in the real world. A few more hours.
    https://youtu.be/2sdZ_pZLRXU

  14. #4874
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    Quote Originally Posted by Flettner View Post
    Home casting at work in the real world. A few more hours.
    https://youtu.be/2sdZ_pZLRXU
    Quote Originally Posted by Katman View Post
    I reminder distinctly .




    Kinky is using a feather. Perverted is using the whole chicken

  15. #4875
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    22nd November 2013 - 16:32
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    Jeez Neil, you're a real legend and, no one can deny it:

    YOU STILL HAVE THE SEXIEST KNEES

    Good job Fletto, you should be very proud...
    "Success is the ability to go from one failure to another with no loss of enthusiasm.

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