R.W Gas Engine

[Rob.Wilson]

Thanks Mad Jack

I will do my best to document the casting and there may be a video too , working on that ,,,,,,,   ,, I am no expert at this casting /pattern making ,still lots to learn and thats the fun in it ,, I have not done much casting for a good few years , I am building this engine to get back into casting  

Here are the patterns i made for  the Rider Ericsson engine (still not finished )  



Regards Rob

[Rob.Wilson]

Hi Lads 

Well not a very productive night ,,,,,,,,, I had planned to use the cnc mill to do a plate with the lettering on , that i would inlay into the side of the pattern ,,,,,,But it died  .
John S  had so kindly helped out and done the G code for me using V carve ,,,,,, Thanks John 

So plan B ,,,,,,,, I am always on the look out for things i can use around the shop for pattern making  and had bought one of those sign making kits that office jokey's use to make desk name tags . So i used the letters from that for the lettering .



Cheers Rob

[andyf]

Rob, I was wondering how you were going to do the letters, and that's really neat  .

Looking forward to the time when "Works" can be used as a verb as well as a noun.

Andy

[Stilldrillin]

Looks great Rob! 

As usual...... 

David D

[John Stevenson]

For Christs sake put a scratch across part of it or knock a corner off, us mere mortals can't stand much more of this.......................

.
John S

[Stilldrillin]

For Christs sake put a scratch across part of it or knock a corner off, us mere mortals can't stand much more of this.......................

John S

He`s not listening John.........        

David D

[Bernd]

That's spme mighty fine pattern work Rob. 

Bernd

[Rob.Wilson]

Thanks Lads

David i am trying hard not to listen to John  

A tad more done  ,, added the fillets to the pattern ,,, makes the job look better instead  of bits of wood  stuck together  , i used wax fillets , the three tools are just some old ball bearings soft soldered to brass bar .and used to press the wax into the corners



First coat of primmer , some filling and rubbing down still needed


Cheers Rob

[Brass_Machine]

Tools noted! great idea... noted. Looking good!

Eric

[Dean W]

These patterns are so nice!  Such a professional looking job.
That's coming from a guy who doesn't do any casting, Rob, but I know good
work when I see it. 

Those castings for the Rider-E are purdy!  As nice as anything I've seen anywhere.
Do you do much work to sell?  I mean, do you sell any casting kits?
Just curious.  I don't mean to seem nosey.

Dean

[Rob.Wilson]

Thanks Dean

Not nosey at all mate  ,,,,,,, I have never sold a casting or engine kit ,, oh tell a lie ,i once sold a spare flywheel i had cast ,that i had found when cleaning out the shop , sold it on Ebay .

Regards Rob

[madjackghengis]

Now look here Rob, that is an excellent set of patterns, and you've done a top notch job in putting them in the log, but isn't it about time to stay up a couple nights, get the finish coat on them, and start casting, so we can see the results?  I can't speak for anyone else, but there's a limit to how much time you get to show off your pattern making skills, and have to get on with the pouring part.  Crimeny, do you think we have the patience of Job?    All kidding aside, those are as fine looking patterns as I've seen, I hope the pour comes out equally well, I'm looking forward to this engine and it's success.  Melting and casting are not something I relish doing in the Carolina summer, so I'm just getting a furnace built, and preparing for the next winter, expecting to do a bunch of casting then, save the wood, and heat the shop with a furnace and melted aluminum and bronze.  I'm looking forward to seeing your casting set up, furnace, sand box and all.  great job on the patterns  mad jack

[Rob.Wilson]

Hi Lads

Jack looks like it will be a week before i get them cast up ,, still have large moulding box to knock up ,  and tongues and poring shank for the larger crucible , Looking forward to seeing you do some casting 

Well this is them ready to go  




Cheers Rob

[John Stevenson]

Bastard, that's my double decker, wondered where it had gone...............

John S.

[Artie]

bloody hell! That is ART... these will have to go on display on a shelf somewhere once they have done their job mate.... too nice to hide away in a box like I do mine (mine deserve to be hidden in a box!)

 

love it love it love it

Rob T

[Divided he ad]

These sure do look nice Rob



But I'm going to have to watch this thread closely to fully understand what you do with all of them

I'm just not anywhere near up to speed with this casting lark???

Bastard, that's my double decker, wondered where it had gone...............

John S.

Such a wonderful way with words John   








Ralph.

[sbwhart]

Great bit of neat work Rob:-

Watch you don't melt that Double Decker, next time a Yorkie bar 

Cheers

Stew

[Stilldrillin]

Rob,




        SIGH......




Shakes head and walks away mumbling........

David D

[madjackghengis]

Rob, I think Artie got it right, That is ART   you make it look to easy, but I don't expect you'll have problems pulling those patterns out of the sand.  Looking forward to the casting, both yours in a week or so, and mine in a few months.  Great job, I might not be able to post any pictures of mine. mad jack

[Rob.Wilson]

Thanks lads 

Well i made a bit of progress yesterday  and made the cores ,,,,,,, they did fit in the kitchen oven ,,just , each core weights about 3.5 kg and took 3 hours to bake ,, i must get an oven for the shop ,, as the smell when baking oil bond cores is minging  .




The two half's were then glued together, with sandweld , core glue



Cheers Rob

[madjackghengis]

Hello Rob, it looks like your cores came out nice, I hope you didn't get in too much trouble for the smell, maybe if you add a little molasses water to the core mix, it makes the oven smell better anyway.  It your moulds come out as nice, you should get some very clean castings, and get on with that engine   three and  a half kilos for a core is pretty heavy, you did well getting them fully baked I would say.  Looking forward to more. mad jack

[Rob.Wilson]

Hi Mad Jack

Oh i got a little bit of grief from the other half ,, so i just went into the shop   

A bit more ,, made up some BIG moulding flasks 2 ft x 15" x 6" ,,,, very heavy when full of compacted sand .

Pattern in drag

parting powder applied

partly rammed up

Drag rammed up and turned over

Cope half of pattern in place

cope fitted and more parting powder

more ramming

all rammed up

flasks split

Pattern removed from drag and runners cut

Pattern removed from cope and gates cut

Core fitted to drag



I may fire the furnace up later and see what comes out

Cheers Rob

[dsquire]

Rob

One word! Amazing. 
 Is there anything that you can't do? I'm looking forward to after the pour. 

Cheers 

Don

[doubleboost]

I recon he could part water
John

[Rob.Wilson]

Hi Don Thanks

Here we go ,,,,,,,,,,,,,, the pore  

Extension added to give a good head of metal  


Pot full of molten ally  



The result  


oops   not enough ally


on the plus side ,, it was raining tonight and i was casting  



Looks like i will be stinking the house out again   better make a BIGGER pot  

Cheers Rob


Edit ,,hi John    i can do that ,,,,,,,,,,,,, just cant work out how much ally i need