The Bucket Foundry

[ken seeber]

Slowly working on the next version of the UHV.

So 3D printed out the final design, then with a few detail changes, upgraded the design on CAD and removed all the machined features, added machining allowance. Used 1.5 deg of draft on all vertical faces. From this, created an .stl file, sent that thru to the slicer programme (Cura 4.6 in my case) and then allowed a scale up (1.2%) to allow for shrinkage. The slicer creates a .gcode file that is used by the 3D printer. What was printed out was the pattern to create a sand mould.

Yesterday I smoothed the pattern and went over it a few times with spray putty. At this point, I came to the conclusion as to why Neil makes so many patterns. It is the beautiful cellulose smell that comes off the spray putty when sanding. Almost therapeutic.

Today I made the first sand mould. Will have to surround it a bit more as it is too close to the edge of the cavity. The patterns has a projection that makes the pattern take up more space. The reason for the projection is that when I turn the sparkplug boss & thread, I can put it into a 3 jaw chuck and the boss will be on centre. After machining it will be cut off.




Hours of fun.

I think Wob was scathing of Dr Joe as he ripped off Yamaha with a design of a cylinder head shape (full diametral bathtub ???) that was a dud. Without history, good or bad, we wouldn't be here now.

Wil, I haven't tried lost PLA, but do have some filament which should be a lot better. It's called Polycast. We did a design of a head shell, but haven't cast it yet, another backburner project.

[husaberg]

I think that would have been pure "fable" - can you imagine trying to get past the Stazi with roadholders down your trouser leg - you would have needed some balls to "leg it"if you had to .... (well, you would still have had some at the start of the chase anyway!)

Pretty sure some of the guards are often racing fans.
remember its goods coming in rather than out.
the oil company guys used to do all the deals with the riders et they were the ones that likely paid fo the etries of the MZ as well.
MZ's idssues was always lack of money to pay riders and get top flight stuff like mags and plugs suspension carbs etc.

[WilDun]

Slowly working on the next version of the UHV. ..........


Wil, I haven't tried lost PLA, but do have some filament which should be a lot better. It's called Polycast. We did a design of a head shell, but haven't cast it yet, another backburner project.

That's the one I was talking about, let me know how it goes, if you're going to use that.
Which CAD are you using now?

I guess that it will need some pretty hi tech stuff if you ever want to directly 3D print metal powder (for sintering)? ..... and no doubt expensive!

BTW, I went back to CURA 4.2.1 instead of 4.6.1 as I was having some prints with layers lifting etc - don't really know why, but the older version is working well.

Pretty sure some of the guards are often racing fans.
remember its goods coming in rather than out.
the oil company guys used to do all the deals with the riders et they were the ones that likely paid fo the etries of the MZ as well.
MZ's idssues was always lack of money to pay riders and get top flight stuff like mags and plugs suspension carbs etc.

All I can say is that I wouldn't have been game to try it under any circumstances with guns and young (trigger happy) guards around!

[husaberg]

T
All I can say is that I wouldn't have been game to try it under any circumstances with guns and young (trigger happy) guards around!

was that a roadholder fork in his trousers or was he juat happy to see them.
I think Kaaden himself might have toted the forks in hindsight.
i will see if i can find it.
a net searh atributes it to Shephard via a shell agent
Another gives the joe swaped engine for forks
pretty sure i have something about shephard

[katinas]

Without history, good or bad, we wouldn't be here now.

Indeed, Joseph Enrich EMC 125 two cylinder engine is awesome. Mr Richards rotary valve Vitesse ( Sun) engine and very interesting, Roger Cramp with his engine. I only found a few photos with Erich Wolf.

[ken seeber]

That's the one I was talking about, let me know how it goes, if you're going to use that.

The pic is of a couple of prints using Polycast. Seems as forgivable as PLA. The wax risers and central downsprue (slightly out of position) are also used to suspend the print using the crossbar (one of two shown) when investing. It is the external water jacket for a KTM 250 motocross engine in a kart. In addition to improving the coolant flow direction, it has the coolant outlet at the back. It's a complex design with lots of lofts and blends that were way above me.

[WilDun]

The pic is of a couple of prints using Polycast. Seems as forgivable as PLA.
The wax risers and central downsprue (slightly out of position) are also used to suspend the print using the crossbar (one of two shown) when investing.............. .... It's a complex design with lots of lofts and blends that were way above me.

You say 'investing' but I'm guessing you are not going to do it in the conventional (thin wall) investment casting way,- will you be surrounding it with plaster/sand in a box?

Those 3D CAD programs are great but it takes a long time with a lot of frustration initially (I'm still at that stage) but I'm loving it - (I have finally settled for Fusion 360 and have done quite a lot of small stuff with it), but nowhere near being a competent user!.

[lohring]

Don't give up on Fusion 360. I'm over 2 years into it and still learning. Solids are fairly straightforward, surfaces are harder, and sculpting is frustrating so far. YouTube has been my source for detail learning. When I get stuck, there's usually someone who has a video on the issue.

Lohring Miller

[WilDun]

Don't give up on Fusion 360. I'm over 2 years into it and still learning. Solids are fairly straightforward, surfaces are harder, and sculpting is frustrating so far. YouTube has been my source for detail learning. When I get stuck, there's usually someone who has a video on the issue.

Lohring Miller

It's good ok - if only it had been around 20 years ago! ...... is it possible to tick a "preference" box to say how you want your reincarnation to be? - then maybe a "resume" box ..... and carry on from there!

[Flettner]

The process of building sand castles again.
Pattern is black colour because of the plumbago I've rubbed in its surface, makes it slippery as @#$/.

[Michael Moore]

Chris Cosentino has updated his Hypermono project blog to tell about the box of Mg engine castings from 3D-printed molds (not patterns) that he recently received. The newest material on the single is at the top of the blog, the Moto2 V4 project is farther down the page. If you've never looked through the entire blog there's tons of very cool stuff on there about designing and building (everything) the bikes.

http://moto2-usa.blogspot.com/

[Flettner]

One core box is giving some grief.
Family have turned up, shed has been placed 'out of bounds', for the moment.

[WilDun]

One core box is giving some grief.
Family have turned up, shed has been placed 'out of bounds', for the moment.

Two steps forward, one backward! - can't wait to see this one hatch out.
Families? - tell me about them?!

[Flettner]

Glueing one of the three water cores in place, tricky bastard, so easy to break.

[Flettner]

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.