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Thread: The Bucket Foundry

  1. #1
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    The Bucket Foundry

    The foundry or metal casting stuff thats been going on the the ESE thread really inspired me to get on with having a go at this stuff.
    If you can cast metal theres really not much you cant do. I dont think its going to be easy, most of it has been a bit of 2 steps forward 1 step back so far.

    Im actually an old hand at this I cast a sinker weight or a sandwich toaster when I was in 4th form metalwork, I suspect not much has changed in the last 35 years since then.

    First I found myself a furnace, looks nice but with the burner it had was struggling to melt cheese, I now have a new burner with a gentle breeze from a small blower.


    One of the first things I wanted to do was copy some parts to make moulds from, Husaberg put me onto a product called Vinamold its a rubbery hotmelt that feels a bit like silicone when at room temp but is a runny liquid at 160C here my first stab at copying the transfers from a RG250 barrell

    P1000689.JPG
    How it arrives, I bought 1.5kg its reusable so if you screw up just throw it back into the pot and try again
    P1000690.JPG

    P1000691.JPG

    P1000692.JPG

    P1000693.JPG

    P1000699.JPG
    left over vinamold ready for next time
    My neighbours diary says I have boundary issues

  2. #2
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    Heres the finished mould of the transfers
    P1000698.JPG


    P1000694.JPG
    P1000695.JPG
    the furnace with the new burner and blower

    P1000696.JPG

    Scrap pile with a ingot from the first sucessful melt

    P1000697.JPG
    Crucible made from a bit of pipe about 5" diameter
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  3. #3
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    This is only the start of the journey, there is so much to learn it kept me awake at night trying to figure some of it out. I can see some almighty cockups in the near future. apart from the LPG its all recycleable.
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    This is great .... looking forward to seeing how it goes.
    - Team ESE -



  5. #5
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    Oh i have some molds............
    Did you watch the series of Vids i posted Mike?
    It has some clever dodges like the degassing etc.
    More research required...

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

  6. #6
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    Quote Originally Posted by husaberg View Post
    Oh i have some molds............
    Did you watch the series of Vids i posted Mike?
    It has some clever dodges like the degassing etc.
    Ah yes this list, plenty of good stuff here, the myfordboy and mr pete are great



    The Myford boy and mrPete22 stuff is worth watching all the videos in the series


    Cores etc

    http://www.alloyavenue.com/vb/archiv...p/t-6993.html?
    http://www.bronzecasting.co.uk/8_san...sodsil_11.html
    http://www.imarketingcenter.com/coresand.html

    materials

    http://www.industrialsands.co.nz/order.html
    http://www.industrialsands.co.nz/resin.html
    http://www.metcast.com/index.php/cat...+Silicate+Core
    http://www.cobcraft.co.nz/StudioTool...tegory=Liquids
    http://www.cobcraft.co.nz/studiotool...tegory=Liquids
    http://www.pottersclay.co.nz/rawmat.htm
    http://www.ryanoresins.com/products/
    How to
    http://www.youtube.com/watch?v=QFLArEHFFHo
    http://www.youtube.com/watch?v=N8DGkC8O9CY
    http://www.youtube.com/watch?v=h-c4_Ukqgx4
    http://www.youtube.com/watch?v=wG9JzeZYPi4
    http://www.youtube.com/watch?v=khEvhjlh_SM
    http://www.youtube.com/watch?v=SQt2RBzepNA
    http://www.youtube.com/watch?v=8tqDL7H-C-o
    http://www.youtube.com/watch?v=TekdQlmvkiU
    http://www.youtube.com/watch?v=hCBRfrPV8BY
    http://www.youtube.com/watch?v=yosykQ-o994

    http://www.youtube.com/watch?v=OedpFHYIkDA
    http://www.youtube.com/watch?v=bzKi4g7jD6I
    http://www.youtube.com/watch?v=khEvhjlh_SM
    http://www.youtube.com/watch?v=Dt2mq...A7F5FD2D3C3088
    http://castinghobbyfaq.bareboogerhost.com/kbond.shtml
    http://home.comcast.net/~oddkins/foundrycasting.html
    http://www.youtube.com/watch?v=0rU2aohquj4
    http://www.youtube.com/watch?v=QWGNl7ijA7g
    Vinamold

    http://fibreglassshop.co.nz/products...meltable-vinyl
    http://www.youtube.com/watch?v=dZGq1...jAnn8E76KP7sQg


    Equipment
    http://www.backyardmetalcasting.com/...emuller01.html
    http://www.ecplabchem.co.nz/content....9-solution-1-l
    http://www.foundry101.com/6.htm
    http://www.budgetcastingsupply.com/index.htm

    Furnace
    http://www.youtube.com/watch?v=jqvWe...endscreen&NR=1
    http://www.dansworkshop.com/2008/03/...ing-furnace-2/
    http://www.submarineboat.com/casting...er_Pot_Furnace
    http://www.flamingfurnace.com/
    http://www.youtube.com/watch?NR=1&v=...ture=endscreen
    http://myfordboy.blogspot.co.nz/p/my...s-furnace.html
    http://www.youtube.com/watch?v=T4SdKN-Kq58
    My neighbours diary says I have boundary issues

  7. #7
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    There is a few i couldn't find where he showed the molding table set up and the muller and the pedestal furnace he has.
    More research required...

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

  8. #8
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    Quote Originally Posted by Yow Ling View Post
    The foundry or metal casting stuff thats been going on the the ESE thread really inspired me to get on with having a go at this stuff.
    If you can cast metal theres really not much you cant do. I dont think its going to be easy, most of it has been a bit of 2 steps forward 1 step back so far.

    Im actually an old hand at this I cast a sinker weight or a sandwich toaster when I was in 4th form metalwork, I suspect not much has changed in the last 35 years since then.

    First I found myself a furnace, looks nice but with the burner it had was struggling to melt cheese, I now have a new burner with a gentle breeze from a small blower.


    One of the first things I wanted to do was copy some parts to make moulds from, Husaberg put me onto a product called Vinamold its a rubbery hotmelt that feels a bit like silicone when at room temp but is a runny liquid at 160C here my first stab at copying the transfers from a RG250 barrell
    . . .


    Mmm. Melted cheese. Used to eat plates of it as a teenager
    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?

  9. #9
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    More research required...

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

  10. #10
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    Heres an interesting foundry video, if it wasnt for the needless slaughter of tens of thousands, I would have said it was great
    My neighbours diary says I have boundary issues

  11. #11
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    Yow Ling, have you lined your crucible with somthing? Ceramic coating? There is a paint on able one. Hot steel straight aginst molten aluminium is not good for the alloy. It does not take much iron to dissolve into the alloy to wreak it. The casting will then not respond to heat treatment. Ok if you are making trinkets but no good if you want sound, high strength engine parts. Also you will need to control your melt temps well, if the alloy is over heated it will burn off some of the alloying components and once again the casting will be left unservicable. Just a few things to consider.

  12. #12
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    Thanks Flettner, Im still taking baby steps, Ill get a proper crucible when one turns up.
    How do you measure the temp of the molten metal ? How do foundries do it, would an exhaust thermocouple do? Can it be done by colour?
    At the moment Im melting my old FXR motor, maybe turn it into FXR footpeg brackets.
    Your 360 cylinder looks great , I suppose you will start it on sunday.
    In my head I envisioned you somehow using a cope and drag to make the mould, but your process was way more complex, do you have any more pictures of that. I understand how the cores and core prints work, I dont get how the parts of the mold were made yet, do you bake them , gas them , ram em?

    That should do for tonight

    Cheers
    My neighbours diary says I have boundary issues

  13. #13
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    I linked these earlier should save Neil finding the pics
    Attached Images Attached Images
    More research required...

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

  14. #14
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    The bag of sand ( in the picture ) is the shell moulding sand I talk about. It is suppiled with a resin coating, this bonds to itself at approx 180 degrees C. You will need a metal die for this ( and the wifes oven ). Some of my dies are made using the CNC but some are made by copying the wood / bondifill moulds into aluminium at the foundry, then turning them into dies. This works well although they do need a little cleaning up so the sand core will slide out easily. I have a few pictures, I'll round them up if you like.
    The other stuff in the pictures is the casting resin, for pattern making. It is good because it doesn't shrink or expand as it sets. It uses two equal parts. It is expensive at $380 for what you see here, adding micro ballons makes it go a little further. I have tried other products but at the end of the day this stuff is worth the money!
    Good on you for having a go, I posted these pictures of making a cylinder ( pattern making ) so others might have a go instead of trying to hack out old cylinders to make them what they never were ment to be. Having the ability to cast intricate parts ( cylinders ) changes the way you will approch projects.
    You will need a temp probe, I made one useing a cheap meter I bought using I think type K wire. Put it inside a stainless steel tube with the bare wire sticking out the end. There is quite a bit to melting alloy properly as you will need degassing pills and a flux of some sort.
    After we had the " incident " with our home foundry I decided it was better to be friends with a local foundry and let him melt the alloy for me, I just make the moulds and put them on the floor next to his moulds.
    The white sand you see is CO2 hardening sand ( cold process ), just pack it in then apply CO2 gas and will harden up instantly. This sand is not as strong as the shell hot sand process but it's good for less inticate parts. I'm not sure what is mixed with the sand, Husaburg will know.

  15. #15
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    I have a fair bit of video of Flettner in the foundry which I am slowly editing. It is pretty interesting stuff. There would have been some of the sleeve valve cylinder getting cast but you forgot to push record on the Go pro Neil . Oh well. We will have to get some of that when you do another casting. Give me a day or so and the first video will be ready.

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