MadModder
Gallery, Projects and General => Project Logs => Topic started by: Rob.Wilson on May 16, 2010, 03:55:09 PM
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Hi Lads :wave:
Well :proj: has struck again ,,,,,,,,, Now that most of my machines are sort of done and the furnace is up and running , i thought i better start yet another engine project , well i wanted some excuse to do some casting , I bought the plans for the R&B Gas engine a few years back because its a nice big-un ,,,,,,Then when i looked at the plans i found out i could not cast the parts due to the size of my old furnace :bang: :bang: :bang:.
So this afternoon i made a start on the patterns for the bed casting , The bed plate as drawn is some what plain ,so i re drew the bed adding a bit more detail , it should look like dis , i hope
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_Bed%20Plate%7E0.jpg) (http://www.nam-engineering.com/cm/albums/userpics/10002/normal_Bed%20Plate%201.jpg)
Progress so far ,,,,,,,,,i only use the straightest / close grained MDF for my patterns .
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020146.jpg) (http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020147.jpg)
Regards Rob
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The grain is running the wrong way on the mounting feet :poke:
John S.
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looks good to me :thumbup:
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Im watchin ... Im watchin..... mdf is crap to work with isnt it.... 'specially that 'straight grain stuff'....
Thats a complex plug mate, you gonna pull it apart for us so we can see up under its skirts? I find this part fascinating... visualising something so you can make it removeable from the sand is not always easy. In essence you are working to create a reverse image.... I think you have to be a bit of a nutter to be able to do it well.... sort of twisted and axxse about.
Hurry up n fire up the furnace... :clap: :bow: :beer:
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Hi John ,,,,, :lol: :lol: :lol: so it is :lol: :lol: :lol: :lol:
Thanks shoey51 :thumbup:
Hi Rob ,,,,,,,,, yep MDF is pretty crappy stuff :lol: :lol: :lol:,, but its the only stuff that dose not warp , NE UK is a tad damp :bang: :bang: ,, I have done a fare bit of head scratching today on this one :scratch: , There will be one pattern and two core moulds , when moulded i will stick the two cores together ,,,,,,,,think it will work
Cheers Rob
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I love it, MDF that is, it's so easy to throw a piece on the mill and get a simple one off pattern from.
Saves hours of work as opposed to cutting out of a billet and they look the biz.
(http://www.stevenson-engineers.co.uk/files/pattern1.jpg)
(http://www.stevenson-engineers.co.uk/files/pattern3.jpg)
These are side columns for a pencil sharpener, only two needed and the pattern is made so it's reversible and can do both sides.
John S.
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ah... well... gee.....
Uhm...John..... do you own a LOT of pencils?
:) :D :D :) :D :) :D :) :D :) :D :) :D :) :) :D :) :D :) :D
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Hi John
Thats some pencil sharpener :lol: :lol: :lol: :lol: :lol: :clap: :clap: :clap: :clap:
Cheers Rob
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Sharpens 7,000 per hour.
Anyway forget this as it's detracting from robs engine post.
Fire that furnace up !!
Rob, check your email.
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What a neat thing this should be! What metal are you using for this casting, Rob?
Please feel free to post excessive photos! An excess will still not be enough in this case.
: )
Dean
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Hi Lads :headbang:
Thanks Dean ,,,,,,,,, the plans call for an ally casting for the Bed ,,,, Which is probably best , help keep the weight down .
Well a little more progress tonight , starting to look like something ,
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020148.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020150.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020151.jpg)
The lower section of the base looks thick , thats cos there is an extra piece of monkey wood holding things together temporary. Still lots to do :D
Cheers Rob
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Rob, is it just the photos or have you not put any draft angle onto the parts?
And just a point about the MDF it can easily swell in width in a damp enviroment, the MR MDF (moisture resistant) is a lot better in thar respect anf generally a lot better to work with.
Jason
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Oh, my...... (http://serve.mysmiley.net/confused/confused0036.gif) (http://www.mysmiley.net/free-laughing-smileys.php)
I`m starting to feel very inferior, again........ ::)
Fabulous work, as usual, Rob! :thumbup:
David D
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Oh, my...... (http://serve.mysmiley.net/confused/confused0036.gif) (http://www.mysmiley.net/free-laughing-smileys.php)
I`m starting to feel very inferior, again........ ::)
Fabulous work, as usual, Rob! :thumbup:
David D
I'm feeling inferior too .... :(
Probably 'cos I am .... :lol:
Really impressive Rob .. :thumbup: :thumbup:
Dave BC
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There will be one pattern and two core moulds , when moulded i will stick the two cores together ,,,,,,,,think it will work
Only way to find out is go! So lets go..... this is a very complex pattern mate, looking forward to seeing it all come out of the sand.....
Speaking of patterns, I found a guy here in Aus who has built his own Gingery shaper..... trying to buy his patterns off him, hes gonna let me know..... these thing are a major investment in time, much more so than most people think...
well done bloke and good luck..... :beer:
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Hi Lads
Thanks David and Dave :lol: :lol: :lol: :lol: :lol: :lol: David ,, starting on your job as soon as i have given this one a coat of paint :)
Hi Jason,,,,,,,, yep most of the draft is on ,,,, still a few nights work left on the pattern ,
Hi Rob ,,,,,,,,, Your right there mate , allot of work in making patterns , i could have welded this up in half a shift :lol: , i hope you get those shaper patterns , building a shaper would be a great project
Cheers Rob
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There will be one pattern and two core moulds , when moulded i will stick the two cores together ,,,,,,,,think it will work
Only way to find out is go! So lets go..... this is a very complex pattern mate, looking forward to seeing it all come out of the sand.....
Speaking of patterns, I found a guy here in Aus who has built his own Gingery shaper..... trying to buy his patterns off him, hes gonna let me know..... these thing are a major investment in time, much more so than most people think...
well done bloke and good luck..... :beer:
Hi all, fine looking pattern, I expect you must have got all the draft right cause no one would try to pull a pattern that complex out of sand without being sure it was going to come up without the sand. :lol: I've only made a few patterns in my life, and machined lots out of billet, it seems making the pattern is as much work as machining the billet, but not so dodgy on accuracy, and once it's cast, lot's less machining, since the casting has its pattern established in, well, the pattern. I'd sure like to see pictures of the ramming up and pulling of the pattern, and certainly the pouring. Looking forward to this build, looks right interesting. :thumbup: mad jack
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Hi Mad Jack ,,,,,,,, i hope i have it right :smart:
A few more photos ,, its now split into what will be the Pattern and core box's ,,, i still have all the fillets to do .
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020154.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020155.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020156.jpg)
Cheers Rob
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I`m starting to feel very inferior, again........ ::)
David D
I'm feeling inferior too....
Dave BC
Oh! I'm starting to feel... education!
(I can feel inferior some other time.) :scratch:
Rob, I'd really like to see just how you put this all together in the sand. Hope you have the time
to take pics of the sequence. Some of us don't visualize this casting stuff as well as others. "Some of us"
meaning, Me.
Dean
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Oh my :bow:
That's gonna be very cool!
Good job so far Rob!
Gotta get over to the U.K.
Eric
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Hi Lads
Thanks Eric , :thumbup: your more than welcome
Hi Dean ,, I will post up all the steps in the moulding and casting process , plenty photos ,few words :lol: this build could turn into a long post .
Tonight work , the pattern is just about finished , it still needs the lettering done , filleting,and a coat of paint , about a good nights work still left in it.
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020161.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020160.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020163%7E0.jpg)
I must put an M&M in the shot for scale :lol: :lol: :lol: :lol: .
Then i had a brain fart ,,,,,,,, will the core fit in the oven :bang: :bang: :bang: :bang: :bang: nope ,,,,,,,,, :bang: ,,,,,,,,,, looks like plan B ,,,,,,,, i will have to get some sodium silicate to use as a core binder .
Cheers Rob
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And so the story continues.... sodium silicate? Is that the co2 activated liquid?
The oven misfit reminds me of a guy in Sydney many years ago... made the evening news..... spent a decade building a yacht in his back yard, by the time he went to remove it the neighbourhood had been all built up including hi tension power lines outside his block..... cranes cant get it out....still sits in his back yard... made it into a granny flat...... :(
More pics? Looking great bloke!
Rob T
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Rob another way would be to stack 4 casting boxes one on top of the other, the middle two would have to be exact height of the pattern you could then pull each pattern from the mould and save making a core. Though it may not pour so easily on its side
Looks good though.
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Hi Lads
Cheers Rob .T ,,,,,,,,, :lol: :lol: :lol: :lol: I have the same problem now i have extended my workshop ,,,,,,,, :bang: IF big IF i finish my 4" Tasker Tractor i cant get it out the garden :lol: :lol: :lol: Yep thats the stuff goes of with CO2 . :thumbup:
Hi Jason ,,,,,,,, I had thought of using CHEEKS ,,,,,,,,,, boxes that go between the cope and drag , but opted for coring ,,,, I may get away with a green sand core ,as they are fairly large ,, The only way to pore this is on its side , fingers crossed
Cheers Rob
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Hi Rob, that's looking like a fine set of patterns and cores, I'm really looking forward to the shots of the ramming of the patterns and the horizontal pour. I hope you have the camera and practice to do a video of the pouring, that'd be nice to see, you've obviously made a pattern or two before, and I'm still working out how you're going to use what you have to ram up a mold. That idea of cheek boxes didn't sound bad, and it was something I could see in my mind. Great work and nice pictures, looking forward, :thumbup: mad jack
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Thanks Mad Jack
I will do my best to document the casting and there may be a video too , working on that ,,,,,,, :thumbup: ,, 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 :dremel:
Here are the patterns i made for the Rider Ericsson engine (still not finished ) ::)
(http://www.nam-engineering.com/cm/albums/userpics/10002/PC180080.JPG)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_PB100063.jpg)
Regards Rob
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Hi Lads :headbang:
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 :bang: .
John S had so kindly helped out and done the G code for me using V carve ,,,,,, Thanks John :thumbup:
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 .
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020166.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020167.jpg)
Cheers Rob
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Rob, I was wondering how you were going to do the letters, and that's really neat :clap: .
Looking forward to the time when "Works" can be used as a verb as well as a noun.
Andy
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Looks great Rob! :clap:
As usual...... :thumbup:
David D
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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
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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......... ::) :bang:
David D
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That's spme mighty fine pattern work Rob. :thumbup:
Bernd
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Thanks Lads
David i am trying hard not to listen to John :lol: :lol: :lol: :lol: :lol: :lol: :lol:
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
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020168.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020169.jpg)
First coat of primmer , some filling and rubbing down still needed
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020171.jpg)
Cheers Rob
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Tools noted! great idea... noted. Looking good!
Eric
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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
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Thanks Dean
Not nosey at all mate :D ,,,,,,, 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
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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? :poke: :poke: 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 :thumbup: :jaw: mad jack
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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 :thumbup:
Well this is them ready to go :dremel:
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020176.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020180.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020181.jpg)
Cheers Rob
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Bastard, that's my double decker, wondered where it had gone...............
John S.
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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!) :bugeye: :thumbup:
:bow: :bow: :beer: :bow: :bow: :beer: :bow: :bow: :beer: :bow: :bow: :beer: :bow: :bow: :beer: :bow: :bow: :beer: :bow: :bow: :beer:
love it love it love it
Rob T
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These sure do look nice Rob :clap:
But I'm going to have to watch this thread closely to fully understand what you do with all of them :scratch:
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 :lol:
Ralph.
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Great bit of neat work Rob:-
Watch you don't melt that Double Decker, next time a Yorkie bar :headbang:
Cheers
Stew
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Rob,
SIGH......
Shakes head and walks away mumbling........
David D
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Rob, I think Artie got it right, That is ART :bugeye: :bugeye: 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. :lol: mad jack
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Thanks lads :beer:
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 .
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020187.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020188.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020189.jpg)
The two half's were then glued together, with sandweld , core glue
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020192.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020190.jpg)
Cheers Rob
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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 :headbang: 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. :nrocks: :poke: mad jack
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Hi Mad Jack
Oh i got a little bit of grief from the other half ,, so i just went into the shop :lol:
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
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020197.jpg)
parting powder applied
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020198.jpg)
partly rammed up
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020199.jpg)
Drag rammed up and turned over
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020200.jpg)
Cope half of pattern in place
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020201.jpg)
cope fitted and more parting powder
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020204.jpg)
more ramming
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020205.jpg)
all rammed up
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020206.jpg)
flasks split
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020207.jpg)
Pattern removed from drag and runners cut
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020208.jpg)
Pattern removed from cope and gates cut
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020209.jpg)
Core fitted to drag
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020210.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020211.jpg)
I may fire the furnace up later and see what comes out
Cheers Rob
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Rob
One word! Amazing. :ddb: :ddb: :ddb:
Is there anything that you can't do? I'm looking forward to after the pour. :D :D
Cheers :beer:
Don
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I recon he could part water
John
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Hi Don Thanks
Here we go ,,,,,,,,,,,,,, the pore :hammer:
Extension added to give a good head of metal :bang: :bang:
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020212.jpg)
Pot full of molten ally :hammer: :hammer: :hammer: :hammer:
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020213.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020219.jpg)
The result :hammer: :hammer: :hammer: :hammer:
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020220.jpg)
oops :doh: not enough ally
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020221.jpg)
on the plus side ,, it was raining tonight and i was casting :)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020217.jpg)
Looks like i will be stinking the house out again :D :D :D :D :lol: :lol: :lol: better make a BIGGER pot :dremel:
Cheers Rob
Edit ,,hi John :lol: :lol: :lol: i can do that ,,,,,,,,,,,,, just cant work out how much ally i need :lol: :lol: :lol: :lol:
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Hi Rob
Other than the fact that you were a bit shy of molten aluminum it looks like it came out pretty good. Thanks for showing us this and I'll be waiting to watch the next pour whenever that is. :ddb: :ddb:
Cheers :beer:
Don
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Hi Don
I though it would be best to show my cock ups as well :lol: :lol: :lol: ,, What i did learn from it was that the core wash i made up was crap , and i need a stronger rack to bake the cores on as they sagged a bit :D , i was pleased with the way the core lined up with the mould :thumbup:
Cheers Rob
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Well..... :scratch:
I never thought I`d see the day....... (http://serve.mysmiley.net/indifferent/indifferent0012.gif) (http://www.mysmiley.net)
He is human, and fallible, after all! :bugeye:
Very well shown Rob! :thumbup:
David D
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Cut it in half and make a single cylinder model :wave:
That'll teach you to nick my double decker.......................... :poke:
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You needed the big crucible (you told yourself that)
John
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Rob
This is going to get expensive, since you've got to send the Mrs shopping again so you can bake more cores... I was wondering how they worked, and now you've shown it. Ta mate.
Joe
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Hi Lads :clap:
David ,,,,,,,,, i mess up all the time , just had years of practice hiding it :lol: :lol: :lol:
John S ,,,,,,,,, :lol: :lol: your lass said i could have the double decker as you need to cut down on them :coffee: :D
John ,,,,,,,,,,, that was the big one :( ,, good job i built a big furnace :)
Hi Joe ,,,,,,,,, What , it would be cheaper to by an oven for the shop :lol: :lol: , looks like i will be going round the second hand shops over the next few days ::)
Cheers Rob
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Heya Rob....
Well, one side looks really nice. I mean outside of not enough alloy, it looks like it will come out as a nice casting next time. I am still very impressed. :bow:
Eric
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Thanks a lot for showing your steps Rob. It sure did a lot to remedy my head scratchin' problem.
I was having a hard time seeing it all come together until you did the cores. Very interesting.
Too bad about he short supply of metal. All the pics are sure appreciated, in spite of that little trouble!
Dean
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Great post Rob,
It wasn't a mistake just a step up the learning curve.
Look forward to the next attempt I'm sure it'll be a keeper.
Stew
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Well Rob, in spite of the bit of shortage in the metal department, the ramming of the pattern, the skill demonstrated in pulling the patterns, setting up the added height for metal, the whole cleanliness of the operation showed you've got it right, just the metal issue is all. By the way, what are the pieces you are melting and pre-heating to melt into your pot? Just curious. I've got to say, the finish on the part of the casting which did come out is as good as I expected it to be, and I think you'll get a good pour as soon as you've got the bigger crucible going. Great job with the pictures, nice and clear, and showing the important details, all in all, pretty good for a failed pour. :nrocks: :thumbup: :jaw: mad jack
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Hi Rob, sorry to see that ..... bugger :doh:
Ive done this a time or two myself..... its all part of the deal isnt it?
..... when I first resurrected the foundry I had a couple of large pours to do so I built a large crucible from steel. Its hard to get decent sized ceramic crucibles way out here... Im in the process of building an even larger one. They work ok but have a limited lifespan.
Looking forward to seeing the end result. I know youll get there. :thumbup:
Rob T
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Hi Lads :wave:
STRIKE TWO ! :lol: :lol: :lol: :lol: :lol:
Here is the result of today's casting .
Looking good so far , enough metal this time ::)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020230.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020232.jpg)
core wash needs spraying on :dremel: when i fined my spray gun
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020240.jpg)
cope side not so good , shrinkage due to not enough metal feeding the mould ,,,,,,,, need to add hot metal risers :smart:
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020239.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020237.jpg)
Mad jack ,,, the things i am melting down are dust/dirt caps that go in the end of hydraulic couplings , they are off 360 excavators ,,, i have a few hundred
Hi Rob T ,,,,,,,, I went for a steel pot :thumbup: ,, i had materials lying around the shop :dremel:
Until the next instalment Rob :thumbup:
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Looks like I need a bigger Ju-Ju doll to stick bigger pins in, this bastard nearly didn't work..............
John S.
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Hi John :lol: :lol: :lol: :lol: :lol: :lol: , so that pian in my chest is you and not all the tabs i smoke ,,,,,,,,,, thats good to no :lol: :lol: :lol:
Looks like I need a bigger Ju-Ju doll to stick bigger pins in, this bastard nearly didn't work..............
John S.
-
I am supposing that, out there somewhere is a few guys who would look at a plug n say "at'll need one riser 'ere n 'nother 'oer 'ere" and be correct.. Unfortunately I aint one of em.... thats a thing experience will tell you.... Rob you are well onto your way with gaining that experience... with that in mind this was a very valuable experiment.
And luckily if it gets to strike three... its simply move onto strike four... no "yer out!"
Good luck mate, Im watchin you....
watchin every thing you do....
But i just cant help but feelin
Someone else is stealin
you away from me
I gotta get that song outta my bloody head....
-
Hi Rob :beer:
I had a feeling it would need some risers some were ,,,, it all ways takes me a good few attempts to get things right ,though i may as well show all steps in getting a usable casting .
On the plus side i do get to fire up the furnace again :D
Cheers Rob
-
and of course all it costs is some gas and your time.... thats what I like so much about it..... :borg: :bang:
-
I'm sure you'll get it next time, Rob! Too bad about the shrinkage.
Can you reuse any of the sand after you've done the pour, or do you make up a new batch each time?
Dean
-
Ohh, Rob! :bugeye:
That was close...... :clap:....... Bugga! :bang:
Onwards and upwards, as they say...... ::)
Good luck to you for episode three! :thumbup:
David D
-
Nice work Rob
Now for the silly ?.
What does a risers do is it some sort of Viagra for casting :lol:
or is it a hole for letting gas out ? :- even more snigers as a double meaning springs to mind. :lol: :lol: :lol: :lol: :lol: :lol:
Stew
-
Cheers Lads :ddb: :ddb: :ddb:
Hi Dean ,, The only sand i cant re-use is the core sand , thats a one shot deal ,, the moulding sand gose back into the bench and gets re-used
Hi Stew :lol: :lol: :lol: :lol: :lol: yep risers are viagra for castings ,, they help out the bits that sag a bit :lol: :lol:
John ,, you need to get a better JU-JU doll , or read the instructions :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :D :D
Cheers Rob
-
Thanks Rob. So, anytime you just do a regular ram up, the sand can be recycled, is that right?
Dean
-
Hi Dean
Spot on :thumbup:, with green sand casting all you have to do is re- temper the sand with water, it has a green bond . The sand dose deteriorate with use so you just add more sand to the pile to freshen it up , the hotter the metal the quicker the clay in the sand breaks down and the life of the sand is reduced .
Cheers Rob
-
John ,, you need to get a better JU-JU doll , or read the instructions :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :D :D
Cheers Rob
Bollox, just read the instructions and I need to dip the pins in the blood of a virgin first.
Well that shags the whole setup up then don't it, chances of spotting a virgin round here are the same as Lord Lucan winning the grand national on Shergar.
Looks like you are safe for the next pour, mutter, bollox, rhubarb and double bollox.
John s.
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John ,, you need to get a better JU-JU doll , or read the instructions :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :D :D
Cheers Rob
Bollox, just read the instructions and I need to dip the pins in the blood of a virgin first.
Well that shags the whole setup up then don't it, chances of spotting a virgin round here are the same as Lord Lucan winning the grand national on Shergar.
Looks like you are safe for the next pour, mutter, bollox, rhubarb and double bollox.
John s.
:lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: tis a good job you cant fined a virgin in it ,,,,,,,, you better fined one for the next pore ,,,,,,,, its sorted :dremel: :ddb: :ddb: :ddb: :ddb:
Cheers Rob
-
Hi Lads
I finally got to fire up the furnace this after noon , added a couple of risers to the mould ,
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020243.jpg)
the riser was full , this shot show how much the riser fed the mould
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020246.jpg)
Looking good ,no sign of any shrinkage , just started to dig it out the sand
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020247.jpg)
Removed from the sand , with the core intact , as i dont want the core sand to mix with the ,casting sand
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020248.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020251.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020252.jpg)
The core sand removed and some of the flash
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020253.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020258.jpg)
Still have to cut the gates off and a bit of a clean up of the parting lines , quite pleased with the core wash for a home brew mix
A few shots of the gating
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020260.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020257.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020259.jpg)
Cheers Rob
Edit : Oh how my arms hurt ,, Just to give you an idea of the weight of each moulding box , imagine 4 , 2 ft x 1 1/2 ft flag stones flat in a stack , then having to lift ,turn , and then reposition them all in one go together , that how heavy each flask is ,, and having to do it a few times cos some lump of sand had fallen out of the mould that should not have ::)
-
:clap: :clap: :clap: :bow: :bow: :bow: :clap: :clap: :clap:
:mmr: :mmr: :mmr:
Knew you would do it!
Now what the heck are risers??
Eric
-
Now that looks good Rob :thumbup: Top marks for Percy verance ( you know the guy? :) )
Oh how my arms hurt
But think of the underlying benefits..... it won't be long before this feels easy and the slightly smaller ones are no trouble at all.... It's amazing how fast the body re-adjusts muscles to do the tasks demanded of it :med:
Now what the heck are risers??
:lol: I was kinda thinking the same thing.... Like an expansion tank?
Feeding during shrinkage? as the outside of the casting sets the risers keep the inside pressurised/fed so it doesn't collapse?? (or am I just inventing stuff in my hectic tired head again? :lol:)
Also, is flash the thin overspill that is cut away where it has seeped into the gap between the moulds?
Looking forward to seeing the rest of this take shape too :dremel:
:nrocks:
Ralph.
-
Woo-Hoo! :thumbup: It looks good!
I just knew third time would be a charm. Good thing John lives in a loose town so he can't put the
hoo-doo on you again.
Thanks very much for answering all my questions, Rob. I'm gettin' a casting edgamakashun here.
The price is right, and the course is first rate!
Dean
-
Cracking job that Man
:clap: :clap: :clap: :clap: :clap: :clap: :clap:
Stew
-
Rob,
I knew you could do it..... Eventually! :thumbup:
Crackin` job! In fact, Poetry in Metal...... :clap: :clap:
Blummin well done :D
David D
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Hi Rob
I had every confidence that you would crack it ... :thumbup: :clap:
Ignore the comments off-stage from (S)Nottingham. (Hawk, Spit, P'toing).
Try a search on Snotingaham :lol: :lol: :lol:
Success is not final. Failure is not fatal. It is the courage to continue that counts.
Winston S. Churchill said that, ... err, ..not to me personally, ... and I think it was while he was still alive ..
I can hear the engine running ...
Dave BC
-
Rob
I have been following along with this and have got quite an education in the art of casting and mold making. You have had a couple of goes at the casting bit but every try was better and you look to have it beat now. The finished casting sure looks a treat. I am looking forward to watching this come to life under your care with the mill and other pieces of equipment. I'll be watching for future episodes. :ddb: :ddb:
For anyone that didn't look up Snotingaham, here is a quote from a google find.
"In 1086 the Normans assumed control: they dropped the ‘s’ from Snotengaham, and preserved Sherwood Forest to provide hunting for Norman kings." :lol: :lol:
Cheers :beer:
Don
-
Looks good Rob
You will have to do another one for the video once i get my self sorted
:D :D :D :D :D
John
-
Excellent work! Truly inspiring mate.... casting rock! :beer: :headbang: :)
On to the next bit...
:poke:
-
Brilliant! :clap:
-
Many thanks LADS for all your comments :beer: :nrocks:
Hi Eric ,, the risers are the two thick ,round things that are close to the mould , and work just as Ralph described :thumbup:
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020268.jpg)
Not allot done , cut the gates of and a bit of a clean up of the casting
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020263.jpg)(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020262.jpg)
Stuck it on the 6X26 mill for size
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020266.jpg)(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020264.jpg)
Just need to fined away to hold it wile i mill the bottom flat ,,,,,,,, oh and finish wiring the mill ::)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020267.jpg)
Cheers Rob :thumbup:
-
Just need to fined away to hold it wile i mill the bottom flat
Cheers Rob :thumbup:
Bluetak ??
John S
-
Just need to fined away to hold it wile i mill the bottom flat
Cheers Rob :thumbup:
Bluetak ??
John S
Do you reckon one packet would do , or just a bit on each corner :scratch:
Cheers Rob
-
Hi
Rob we had some cylinder heads to fly cut at work there were no suitable mounting points so we set them on 4 big blobs of dry wall adhesive (plaster of parris type stuff) this worked a treat nice gentle cuts
John
-
Just need to fined away to hold it wile i mill the bottom flat
Chewing gum ( doublemint of course for extra flavour )
Tim
-
Just need to fined away to hold it wile i mill the bottom flat
Cheers Rob :thumbup:
Bluetak ??
John S
nah .... he could sit it in a basic shuttered pour of plaster of paris - but there was a clue in one of Rob's earlier posts .... instead of using plaster of paris, because Rob's into hot casting (but he want's something of lower melting point than the Ali) he'll just pot round the engine with chocolate, with a biscuit base, and some peanuts for aggregate? :coffee:
-
Just need to fined away to hold it wile i mill the bottom flat
Cheers Rob :thumbup:
Bluetak ??
John S
nah .... he could sit it in a basic shuttered pour of plaster of paris - but there was a clue in one of Rob's earlier posts .... instead of using plaster of paris, because Rob's into hot casting (but he want's something of lower melting point than the Ali) he'll just pot round the engine with chocolate, with some peanuts for aggregate? :coffee:
:lol: :lol: :lol: :thumbup:
David D
-
Like the old UK advert for a well know chocolate bar.
"What's got peanuts in every bite ?"
Squirrel shït
.
John S.
-
Wow! This series is very impressive to me. So many questions have be answered and techniques learned by by watching this project. Thanks for your postings and I look forward to following this as it continues.
Al
-
:lol: :lol: :doh: :lol: :lol: :lol: :doh: :lol: :lol: :lol: :lol: :doh:
Rob ::)
-
Wow! This series is very impressive to me. So many questions have be answered and techniques learned by by watching this project. Thanks for your postings and I look forward to following this as it continues.
Al
Thanks Al ,,,,,,,,,, you still casting ?
Regards Rob
-
Thanks Al ,,,,,,,,,, you still casting ?
Regards Rob
Funny you should ask. ::) I was working a project just this weekend on a lower mount for the quill on my mill, to mount the igauging indicator I just bought. Nothing fancy like what you have been doing, but it was a first attempt with split pattern. It's not totally done, but it's turning out OK.
A couple of pictures:
(http://i61.photobucket.com/albums/h49/apowellx/Mill%20mount/IMG_1052.jpg)
(http://i61.photobucket.com/albums/h49/apowellx/Mill%20mount/IMG_1053.jpg)
(http://i61.photobucket.com/albums/h49/apowellx/Mill%20mount/IMG_1054.jpg)
Hey! It even fits! :D
(http://i61.photobucket.com/albums/h49/apowellx/Mill%20mount/IMG_1059.jpg)
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Hi Al :clap: :clap: :clap: :clap: :clap:
Great job ,the casting came out very nice and clean ,, sure dose save allot of material making a casting :thumbup: .
Hope to see more of your casting :D
Regards Rob
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Hi Lads :wave:
Mulled a few ideas around for holding the casting to the mill , from blue tack to making a large vice with separate jaws that bolt to the mill table (future project ) any way had a brain fart and ended up poking a couple of holes in the casting ,so i could have something to grip.Them i welded a short lenght of 3/8 bar to a couple of clamps
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020287.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020286.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020284.jpg)
The casting was then shimmed up on the mill and clamped down
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020274.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020275.jpg)
Then off we go
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020279.jpg)
job done
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020281.jpg)
First job on the 626 mill ,, works well :D
Cheers Rob
-
Neat thinking Rob! :thumbup:
David D
-
WELDED
Good heavens man, I'd have expected some custom clamp with a mirror finish and ground to 3 nano microns of the clamps life.
What is the world coming to ? welded ??
John S.
-
Actually, John........
You`re right! :lol: :lol: :lol:
David D :thumbup:
-
Actually, John........
You`re right! :lol: :lol: :lol:
David D :thumbup:
Stop egging him on :lol: :lol: :lol: :lol: :lol: :lol: :lol:
Rob :D
-
WELDED
Good heavens man, I'd have expected some custom clamp with a mirror finish and ground to 3 nano microns of the clamps life.
What is the world coming to ? welded ??
John S.
3 nano microns ?? :scratch:
Can I ask why you still persist in using the long-obsolete and archaic SI system of measurement ?
The correct dimension should read '3.187 atto FOOTBALL PITCHES' , or, alternatively, '2.613 femto DOUBLE-DECKER BUSES'.
I have sent a copy of your post to Tiff Needell .. together with a strongly worded note.
Let us have no more of this .. please use the current UK standards. Pitifully low as they are.
:lol: :lol: :lol:
Dave BC
-
Good thinking with those pin clamps, Rod. That welding looks very precise, to me! ; )
Gee, that casting looks as good on the inside as it does on the outside, too.
Dean
-
Cheers Dean ,,,,,,,,, The casting is surprisingly good , only one spot witch has some porosity :D
This post may have way to many photos ::) ,,,,,,, I machined up the casting over the past two nights ,this is how i did it .
The casting had to be marked out to give me some reference points to work from and to make sure the casting would machine up correctly .
the casting was set up on the surface plate using a couple of small screw jacks and an angle plate so i could mark a datum line through the center of the casting .
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020314.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020316.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020317.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020319.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020318.jpg)
once i was happy with the position of the casting the centre line datum was marked , this will be used to set the casting up on the mill
Next the position of the crank centre was marked out and all other parts to be machined as a guide so that i dont machine off something that i should not :bang:
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020323.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020324.jpg)
That done time for some machining :ddb: , I wanted to mill all parts without having to reposition the casting once bolted to the mill , so i decided to use the Aceira F3 HZ/V mill , I just had enough travel on the mill , machining the casting this way i would not have any alignment issues.
The casting was set up on the mill using the datum line
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020326.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020325.jpg)
Had to use my small doodad , that lets me have a tee slot were i need it as i was very limited to were on the mill the casting could go.
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020327.jpg)
With it all set up the cylinder end was machined up
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020330.jpg)
next the bearings , the table on the mill tilted to 18 degs
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020333.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020334.jpg)
next picking up the datum the inside of the bearing supports were machined
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020337.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020338.jpg)
that done i could machine them to the correct thickness
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020339.jpg)
then the tops were machined
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020344.jpg)
Then off with the vertical head so i could machine the bosses for the timing gear and stuff with the tooling in the HZ head , One of the previous operations machined off the crank centre , so a temp datum was fitted.
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020345.jpg)
with that located it was a case of across a bit down a bit using the dials to locate the centre fro the timing gear shaft
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020347.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020349.jpg)
After drilling the hole was bored to size using a very small boring head
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020351.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020355.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020356.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020357.jpg)
Then the rest of the bosses were machined up
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020359.jpg)
Job done ,,,,,,,,, well still need to do the bolt down pads
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020360.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1020363.jpg)
Cheers Rob
-
Well I suppose that will have to do.......
John S.
-
Well I suppose that will have to do.......
John S.
But are you happy with the amount of swarf in the shots ,John :D
Rob
-
Wow
-
no, seriously...wow
-
I can just see a historian in 300 years time trying to research the RSW Engine Works.... was it some like BMW?..
mate this looks soooooo proffesional..... like it came from a very good factory with automation..... :clap: :beer: :headbang: :borg:
Great stuff...
Rob T
-
very nice
:clap: :clap: :clap: :clap: :clap: :clap:
John
-
Have you done this before, then?
-
Rob
Another fine lesson in machining. I look forward to these posts like some look forward to their soccer/football or hockey games. :ddb: :ddb:
Even John seems somewhat satisfied for a change. :lol: :lol:
Cheers :beer:
Don
-
Rob, no one will ever know that this was made by a person. It's too good!
Great work, and done up right on the first try!
:clap:
Dean
-
Only one word comes to mind, "OUTSTANDING". :jaw: :thumbup:
Bernd
-
:bow: :bow: :bow:
That's some seriously nice work. I learned quite a bit from the pictures alone. :smart:
Eric
-
Fantastic stuff! I have to make that "dodad" that let's you have a T slot where you need it! Thanks for the inspiration.
-
Awesome work and many chips :)
I like the aux t-slot plate..great idea.
Also, nice Aciera milling machine you have there...I got an older style F3 (the more round version), also with the universal table, and I love it :)
Stefan
-
I can`t add anything more....... It`s all been said!
Rob....... That`s blummin good work, and well shown too! :clap: :clap: :thumbup:
David D
-
:jaw: :bugeye: :thumbup: :bow: :bow: :bow: :bow: :bow: :bow:
what more can I say that hasnt been said :clap: :clap:
-
:jaw: Stunning Rob - your craftsmanship is a real inspiration. In the past we lauded famous authors for their prose - your words+pictures are up there too! :bow: :bow: :bow: :bow:
Dave
-
p.s. I thought you would have recycled all that swarf into newly-cast bearing caps by now as well ! ::)
-
Great bit of work Rob a masterclass in machining a casting.
Very well shown.
Stew
-
Hi Rob
Another fine lesson in machining :nrocks: :nrocks: :nrocks:
Thanks for sharing your talent..
Best regards
Mauro
-
:bow: :bow: :bow: :bow: :bow: :clap: :clap: :clap:
I can only add more of the same to what everyone else has said: Bloody excellent work, that's a REALLY tidy looking bit of machining. I'm in awe of your little t-slot doodahd, I must have one of those myself.
(http://helmies.org.uk/AllHailTheKing.gif) (http://helmies.org.uk/jumpingsmileys.gif)
-
So,
I missed this first time around :scratch:
Looking very good Rob :thumbup: And as thers have said I think I need a t slot doofor like that one you got there... Might save some swearing?
I'll also go on the lookout for that washer making device you show in the 20th picture down (or the 8th up) Seems a little elaborate for just one ali washer? But hey, if you got the machinery and the stock what the hell I say :dremel: :)
Looking forward to seeing the rest develop,
Ralph.