The Bucket Foundry

**WilDun** · 11th August 2016, 21:25

Originally Posted by husaberg

how does it compare price wise?
As per discussion off the same site Neil

I don't think I'll be doing much experimenting with any of that stuff! - they are saying "free delivery within NZ"! - I should damn well think so with costs like that!
Think I'd better wait till I've got something specific to make before trying it, those prices are definitely not for the faint hearted muddler (like myself).

**husaberg** · 11th August 2016, 21:33

Originally Posted by WilDun

I don't think I'll be doing much experimenting with any of that stuff! - they are saying "free delivery within NZ"! - I should damn well think so with costs like that!
Think I'd better wait till I've got something specific to make before trying it, those prices are definitely not for the faint hearted muddler (like myself).

15% discount for gold card Will

Okay I made that up..

**WilDun** · 12th August 2016, 07:55

Originally Posted by husaberg

15% discount for gold card Will
Okay I made that up..

Yes, well, sometimes just being the old pensioner works as well as a goldcard! - In some cases the goldcard (which I have only used a couple of times on the ferry) seems to annoy some people , but as I said somewhere before there are some good guys willing to give you a good discount ie. if you are there in person and so long as you don't expect it, or be arrogant.

One guy offered me a brand new crucible (for free!) unfortunately it was too big for my purpose - I could have taken it and sold it on I guess, but I wouldn't do that.

**Flettner** · 12th August 2016, 08:42

Originally Posted by WilDun

Yes, well, sometimes just being the old pensioner works as well as a goldcard! - In some cases the goldcard (which I have only used a couple of times on the ferry) seems to annoy some people , but as I said somewhere before there are some good guys willing to give you a good discount ie. if you are there in person and so long as you don't expect it, or be arrogant.

One guy offered me a brand new crucible (for free!) unfortunately it was too big for my purpose - I could have taken it and sold it on I guess, but I wouldn't do that.

Will, yes that would be terrible to sell it on, but you could have given it away to say, someone in the Waikato reign

Those urethane product are expensive, even the rencast was dear enough but with the rencast you essentially got eight liters (with filler). Under those terms quite cost effective at $380 a kit. I miss Rencast

Had a look through Neals Foundry (Porirua) on the weekend, I see they use chemical set sand (not green sand or CO2 set) but they reuse / refurbish it. Set up for production, so my one off loose patterns were a pain for them, that's why my castings were $90 each, fair enough. I'll have to kick my out doors foundry into life again for this one off stuff, now that the weather will be getting better. Clutch case castings are away being heat treated at the moment.

**Ocean1** · 12th August 2016, 08:48

Originally Posted by Flettner

Will, yes that would be terrible to sell it on, but you could have given it away to say, someone in the Waikato reign

Those urethane product are expensive, even the rencast was dear enough but with the rencast you essentially got eight liters (with filler). Under those terms quite cost effective at $380 a kit. I miss Rencast

Had a look through Neals Foundry (Porirua) on the weekend, I see they use chemical set sand (not green sand or CO2 set) but they reuse / refurbish it. Set up for production, so my one off loose patterns were a pain for them, that's why my castings were $90 each, fair enough. I'll have to kick my out doors foundry into life again for this one off stuff, now that the weather will be getting better. Clutch case castings are away being heat treated at the moment.

If you're still in town I found that araldite, you can have it. It's old but it should work OK.

**Flettner** · 12th August 2016, 09:29

Originally Posted by Ocean1

If you're still in town I found that araldite, you can have it. It's old but it should work OK.

Thank you, I'd love to give it a try. next time I'm down I'll give you a call.

**WilDun** · 12th August 2016, 22:37

Originally Posted by Flettner

Will, yes that would be terrible to sell it on, but you could have given it away to say, someone in the Waikato reign

Yes that was a few years ago when I first thought of doing a foundry and I had actually considered giving it to someone, then I thought that all the hundreds of enthusiastic Kiwi foundrymen on this forum would have missed out and really that would be unfair! so I turned it down - I'm sure you'll understand.

Was there anything wrong with sodium silicate moulds as well as cores for home casting? seems like a cheap alternative to all these exotic expensive goos you can buy?
Of course I do realize that it can't be reused again but so long as you've got a decent length of driveway , it could be easily disposed of and still be a cheap alternative.

What about the Kihikihi speedway track? - might be ok on that!

**Flettner** · 18th August 2016, 18:26

Clutch case machined and fitted. Heat treated CC601 looks nice in my opinion and leaves a high quality finish where machined.
Sacrificial lugs have been sacrificed.

**WilDun** · 19th August 2016, 10:20

Originally Posted by Flettner

Clutch case machined and fitted. Heat treated CC601 looks nice in my opinion and leaves a high quality finish where machined.

Looks great - is that bottom end also to be used for other experimental engines? - probably won't be long till we hear it/them in action I guess.

**Flettner** · 19th August 2016, 11:08

Originally Posted by WilDun

Looks great - is that bottom end also to be used for other experimental engines? - probably won't be long till we hear it/them in action I guess.

Yes several different cylinders. First will be the sleeve engine, followed by the 153cc twin port cylinder. Best is saved till last, the HCCI, epicycloid crank, FOS/Ryger test engine. Possibly another slider cylinder as well ( the one I started but never finished).
Best bit is all these variations will be able to be run in the YZ frame, assuming they run

**Flettner** · 19th August 2016, 19:34

Here is a sneak preview of the FOS/Ryger cylinder. Epoxicast is working now (using the right release agent, who would have thought), original shapes and the core boxes made from them.

**Flettner** · 19th August 2016, 19:35

Original FOS core box and shape it was made from.

**Flettner** · 19th August 2016, 19:40

Epoxicast shapes made in these core boxes are the foundation of the built up composite pattern. Water core next, first make the water core shape then cast a core box from it. Next weeks night time entertainment.

This is the cylinder that will end up with the HCCI piston on top and/or a sparkplug as well, case reed inlet will be blocked off. I'm finishing off the epicycloid crank to run under this cylinder, so tight crank case pumping and oil sealed off in the bottom end.
Epoxicast is not a patch on Rencast but it will do for now, a bit of filling required with the spotty finish. The idea for this engine is to regulate it via exhaust throttle and fueling, with the inlet being open, the inlet being the three radial ports at 120 degrees in between the exhausts. These straight in to the cylinder transfers also feed the crank case via piston port at TDC. There will be three pulsed injectors in these three ports but only supplying fuel when the crank case is drawing air. Flow into the cylinder at BDC will be air only. I think this is a better idea than Zurg.

**Ocean1** · 19th August 2016, 20:55

Originally Posted by Flettner

Epoxicast shapes made in these core boxes are the foundation of the built up composite pattern. Water core next, first make the water core shape then cast a core box from it. Next weeks night time entertainment.

This is the cylinder that will end up with the HCCI piston on top and/or a sparkplug as well, case reed inlet will be blocked off. I'm finishing off the epicycloid crank to run under this cylinder, so tight crank case pumping and oil sealed off in the bottom end.
Epoxicast is not a patch on Rencast but it will do for now, a bit of filling required with the spotty finish. The idea for this engine is to regulate it via exhaust throttle and fueling, with the inlet being open, the inlet being the three radial ports at 120 degrees in between the exhausts. These straight in to the cylinder transfers also feed the crank case via piston port at TDC. There will be three pulsed injectors in these three ports but only supplying fuel when the crank case is drawing air. Flow into the cylinder at BDC will be air only. I think this is a better idea than Zurg.

Very interesting. Or it will be when I get my head around it.

Is common practice for some resin moulding processes to stick the mixed resin in a vacuum chamber for a while, to get rid of them bubbles.