Author Topic: My new foundry (Read 36537 times)

NormanV · « **on:** September 24, 2013, 03:48:36 PM »

I had to leave my old foundry behind when I returned to the UK from abroad and now need one for my next project. I was living in the Falkland Islands and sourcing materials was a bit of a problem but I managed to find everything that I needed for next to no cost. For fuel I used peat that was free. I successfully produced a number of castings.
I thought that being in the UK it would be easier, not true, nothing is available locally and I have had to search Ebay or travel long distances to get materials.
At long last I was ready to start building today I obtained an old vacuum cleaner from a scrap yard that was the right size and is on a wheeled trolley, plus the motor will do for the air supply.
The drum is stainless steel which should solve the rusting problem that I had with my old one.

NormanV · « **Reply #1 on:** September 24, 2013, 03:57:53 PM »

I found a supplier of refractory materials that were very helpful, good prices and no minimum order.
http://stores.ebay.co.uk/PotteryProUK . I can thoroughly recommend them ( I have no connection with them)
I lined the bottom of the drum with 3" thick fire bricks which cut reasonably easily with a club hammer and a bolster. I knocked the corners of the bricks off with the bolster to enable me to fit seven bricks around the sides.

doubleboost · « **Reply #2 on:** September 24, 2013, 03:59:16 PM »

Looking very nice
Are you going to use propane to heat it
John

NormanV · « **Reply #3 on:** September 24, 2013, 04:03:42 PM »

I then packed the gaps with ceramic fibre
(I rather foolishly bought 15kg of offcuts which consists of strips approx. 30" x 3" x 1", I used about 1/2 KG and have a lot left over, anybody want some for the cost of the postage and bag from the post office?)

NormanV · « **Reply #4 on:** September 24, 2013, 04:15:11 PM »

It is now completely lined, tomorrow I will be making the lid.
For the lid I will be using 50mm thick ceramic fibre board which I intend to plaster over with refractory cement.
John, I am hoping to be able to use it initially with charcoal and eventually with propane, unfortunately there is no free peat in Lincolnshire!
I plan on having the crucible standing on two pieces of fire brick that will enable the propane flame to surround the crucible as there was already a tuyere hole that leads straight into the drum and not at an angle to prevent the flame from burning directly on the crucible.

vtsteam · « **Reply #5 on:** September 24, 2013, 07:32:28 PM »

Looks very familiar!

http://madmodder.net/index.php/topic,8574.0.html

NormanV · « **Reply #6 on:** September 25, 2013, 10:59:01 AM »

Today I worked on the lid, I cut the ceramic fibre board to shape on the bandsaw and wrapped it in wire mesh from a recycled bird cage and have started to plaster it with refractory cement.
I had intended my furnace to be mobile as it is on wheels, but it is so heavy that I can barely move it!

awemawson · « **Reply #7 on:** September 25, 2013, 11:14:43 AM »

Quote from: vtsteam on September 24, 2013, 07:32:28 PM

Looks very familiar!

http://madmodder.net/index.php/topic,8574.0.html

Hey Steve, I hope that you are claiming Royalties on that 'furnace on wheels'

NormanV · « **Reply #8 on:** September 25, 2013, 11:32:12 AM »

I've got all the patterns made for my next project, a milling machine. The largest will require approx. 11kg of aluminium, I need to start collecting scrap.

Andrew, The wheels will be mostly for show, it is just too heavy to move. I had planned on moving it in and out of the workshop.

awemawson · « **Reply #9 on:** September 25, 2013, 11:35:54 AM »

Norman,

If you look back in Steve's thread he lost his in the snow last year

Andrew

tom osselton · « **Reply #10 on:** September 25, 2013, 12:22:48 PM »

Snow will be here soon maybe a month to go or so usually by haloween.

NormanV · « **Reply #11 on:** September 25, 2013, 12:59:02 PM »

Andrew, we had hardly any snow last year here in Lincolnshire, we didn't have a particularly hot summer this year either!
Norman

Pete. · « **Reply #12 on:** September 25, 2013, 01:24:50 PM »

Our summer down in Kent has been one of the finest I can recall.

vtsteam · « **Reply #13 on:** September 25, 2013, 01:35:02 PM »

Norman, I had the same problem you do. It was very heavy for the existing vacuum cleaner wheels. The main problem was the location of the wheels. There wasn't enough clearance under the barrel for rolling well on grass, and the handle was located too far aft -- when leaned over enough to clear the wheels, a large proportion of the weight was on the hands. Also the handle was low, so you basically ended up stooped pulling a lot of weight and snagging on things.

Now, I think wheels can be a good idea, but it just has to be proportioned differently than it was as a vacuum cleaner. 3 or 4 wheels would work, for instance. Or even a moving truck would work with a furnace with no wheels, because the proportions are correct on the truck.

On mine, I finally opted for skids, and that has worked well for infrequent moves on grass.

Looking forward to reading about your progress!!

awemawson · « **Reply #14 on:** September 25, 2013, 01:48:05 PM »

Quote from: Pete. on September 25, 2013, 01:24:50 PM

Our summer down in Kent has been one of the finest I can recall.

Pete, I didn't want to 'rub it in', but same here as we are next to you in East Sussex

Andrew

vtsteam · « **Reply #15 on:** September 25, 2013, 03:28:37 PM »

btw, Norman, the wheels and attached handle eventually became this:

tom osselton · « **Reply #16 on:** September 26, 2013, 02:46:35 AM »

well you could always try something like this, it could slip in to the pin that is connected to the base so when the handle is lowered it suspends the furnace to be wheeled

chipenter · « **Reply #17 on:** September 26, 2013, 03:17:32 AM »

Quote from: Pete. on September 25, 2013, 01:24:50 PM

Our summer down in Kent has been one of the finest I can recall.

The autumn is turning out nice as well in the south of Kent .

Jeff

NormanV · « **Reply #18 on:** September 27, 2013, 08:43:41 AM »

Further work on the lid, I made a band of steel to clamp around the lid that had lugs attached that gives a place to attach the lifting handle yet to be designed. I then plastered over the whole of the lid with refractory cement.
I ran a small fire in it last night and noticed that the smoke escaped around the edges of the lid more than through the hole. This morning I applied a layer of cement, covered it in cling film and then pressed a flat board onto it which has given me a nice flat surface. I have done the same with the lid, this should give me a good seal. When it is dry I will try another fire and I hope to see no leakage.

vtsteam · « **Reply #19 on:** September 27, 2013, 09:10:17 AM »

Looking good! Norman, what is the bore of your furnace?

sparky961 · « **Reply #20 on:** September 27, 2013, 09:16:39 AM »

I have to applaud your resourcefulness. Good re-use of items!

NormanV · « **Reply #21 on:** September 27, 2013, 11:22:20 AM »

The internal dimensions are 9 1/2" dia x 21" high.
I tried moving it today, I was concerned that the handle might not be strong enough but it seems it will be ok if I am careful.
Now I've got to buy steel tube for the crucible and get it welded.

Surely there is somebody who would like the ceramic fibre blanket that I have left over. I have approx. 60 strips 24 x 3 x 1" ? It's yours for the cost of the postage or collect if you are near Skegness

DavidA · « **Reply #22 on:** September 27, 2013, 03:00:31 PM »

Norman,

Thanks for your kind offer. It is about time I started on my furnace, so I will take half of it off your hands. No point in me taking it all if I can't use it.

I'm over in Keighley so I can have a run out to the coast and collect. It will be next weekend though. This weekend is used up.

PM me with your address and a suitable time.

Dave.

vtsteam · « **Reply #23 on:** September 27, 2013, 04:40:32 PM »

Quote from: NormanV on September 27, 2013, 11:22:20 AM

The internal dimensions are 9 1/2" dia x 21" high.

That's a nice size. I wish mine was at least an inch larger bore.

I sometimes wonder if I could make a boring tool with a carbide insert, an external frame of some sort to guide it and enlarge the bore a little using a half inch electric drill.

NormanV · « **Reply #24 on:** September 27, 2013, 06:42:55 PM »

I'm sure that it would be possible to bore it out, but not on mine as I don't have solid fire cement between the bricks.

All of the ceramic blanket has been claimed.

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Author Topic: My new foundry (Read 36537 times)