MadModder
The Shop => Metal Stuff => Topic started by: doubleboost on November 16, 2009, 04:41:05 PM
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Hi
I have not posted for a while (work sucks)
At present we are building the Hasbruck no 8 v twin steam engine.
A brass fly wheel wopuld look good having no 5 inch bar to hand we decided to have a go at casting some.
Some fire bricks charcoal and a leaf blower were quickley assembled.
A crucible was fashioned from a length of 5 inch stainless pipe and the fire lit.
After 3 bags of charcoal and 1 hour we had molten brass some brazing flux was added to the mix and a simple mold made from sand.
The metal was poured sadly not enough but it worked.
As the brass cooled we cooked lundh on the hot bricks LOL
I took a light cut in the lathe and was very happy with the results.
Next tine i will try coke as a fuel
(http://i261.photobucket.com/albums/ii63/john970s0/007.jpg)
(http://i261.photobucket.com/albums/ii63/john970s0/009.jpg)
(http://i261.photobucket.com/albums/ii63/john970s0/017.jpg)
(http://i261.photobucket.com/albums/ii63/john970s0/014.jpg)
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Nice try with the casting. What size pieces did you melt?
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After my earlier attemp to cast brass cwe decided to build a propper furnace.
A nice stainless beer keg was accuired the top chopped off and a base constructed.
A start was made on a propane burner (bunsen burner but bigger)
(http://i261.photobucket.com/albums/ii63/john970s0/004.jpg)
(http://i261.photobucket.com/albums/ii63/john970s0/002.jpg)
(http://i261.photobucket.com/albums/ii63/john970s0/012.jpg)
(http://i261.photobucket.com/albums/ii63/john970s0/007-1.jpg)
(http://i261.photobucket.com/albums/ii63/john970s0/014-1.jpg)
I now need some castable refractory cement any suppliers in north ease \england
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Nice job. the food does look good...
Was this your first attempt at casting?
Eric
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Hi
Eric
Yes this was my first try we needed sone 6 inch brass bar for a flywheel
I did cast some alloy at school (30 years ago)when they let you do things
The bras we cast machined up well just not enough to fill the mold
Regards
John
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The bras we cast...
So, what were you making? Costumes for a production of Wagner's Ring Cycle? :)
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Hi
Built a bigger burner i now have some propper heat .
This link should take you to a short video
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Brilliant, absolutely brilliant ....... thanks for showing that ... nice touch at the end too :clap:
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You have got to enjoy your self lol
John
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That was a super video, and a great final outcome (the casting looked pretty good, too :lol:).
I suppose you will be able to turn the patio central heating radiator off for a day or so, while the furnace cools down.
Seriously though, thanks for showing it.
Andy
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It may have been a lot cheaper to buy a lump of 6 inch brass bar , but not nearly as much fun.
I am now looking to cast cylinder covers and valve chest covers.
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It may have been a lot cheaper to buy a lump of 6 inch brass bar , but not nearly as much fun.
Exactly ............ Well done lads :bow:
CC
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(http://i261.photobucket.com/albums/ii63/john970s0/008-1.jpg)
Cylinder covers
We are starting to enjoy melting metal
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Nice job! Want to try that sooo bad. One day!
Eric
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Me, too. The one thing that is stopping me, is that I already have so many projects. Getting into yet another would mean they all suffer even more time deficit.
Nice finished part. I have one quibble, though. You spent all that time on the casting, and yet machined it all. It looks too good - no evidence at all of the work that went into making the casting. I'd say you should leave the outside diameter in an as-cast state. I know I'd want to, so I could point to it and say, "I made that from scratch".
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Me, too. The one thing that is stopping me, is that I already have so many projects. Getting into yet another would mean they all suffer even more time deficit.
I could not have put that better as I too would love to have a go at casting ...
I'd say you should leave the outside diameter in an as-cast state. I know I'd want to, so I could point to it and say, "I made that from scratch".
Yeah, that real "scratch" init :clap: :clap: :clap:
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I just had to say well done guys. This is an extremely rewarding facet to our hobby and I'd encorage anyone with an ounce of common sense to have a go. Pics attached of the cylinders for the latest build 25mm bore 40mm stroke from start to finish. Cheers and good luck. Artie
(http://i293.photobucket.com/albums/mm54/artieonedge/06012010584.jpg)
(http://i293.photobucket.com/albums/mm54/artieonedge/20012010675.jpg)
(http://i293.photobucket.com/albums/mm54/artieonedge/21012010695.jpg)
(http://i293.photobucket.com/albums/mm54/artieonedge/25012010717.jpg)
(http://i293.photobucket.com/albums/mm54/artieonedge/31012010761.jpg)
(http://i293.photobucket.com/albums/mm54/artieonedge/05022010874.jpg)
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Very nice
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sorry Boost, didnt mean to hijack your thread, just hoping to inspire those who might want to have a go at casting... :beer:
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Hi
Artie
Nothing to be sorry about , the more posts the better ,this casting is certainly interesting stuff.
I have been making casting flasks all week (i hate working with wood).
I am hoping to cast a brass name plate for the house ,if i can keep the wife happy all will be well.
Regards
John
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Hi
Visited Rob Wilson yesterday
He gave me some good advice regarding casting
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Loved it! :clap: :clap:
Thanks for showing..... :thumbup:
David D
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Me too, bet that was good fun day...
two Q's, whats the skewer poked into the sand for .. air escape :scratch:
and what was the black stuff you sprayed ... a release compound :scratch:
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Hi John :headbang: :headbang:
Great video ,,,,,,,,,,NICE ONE :thumbup: :clap: :clap: :clap: :clap:
Thanks for giving me the chance to pop over to your shop :dremel:,,,,,,,,hope to see some photos of tonights casting
Regards Rob
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That's better'n anything on TV. Ever. Thanks a lot!
You could do as many of these casting videos as you like. Great stuff.
Who's the lucky feller chomping on the bacon sandwich?
Dean
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Hi
The holes are to vent the mould the black spray is powderd graphite mixed with alcohol (top tips from Rob Wilson)
The piece we cast was in fact full of blow holes (bronze far to hot)
Rob came over on monday we re cast them in open top moulds the results were perfect
I will put some pictures of the machined parts up
Regards
John
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That looks great fun, I'd love to have a go myself - you're wife must be much more understanding than mine :bow:
Where do you get so much brass / bronze from ??? Would plumbing fittings be any good for home casting ?
Cheers
Jim
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The bronze cylinder covers cast in the open moulds
(http://i261.photobucket.com/albums/ii63/john970s0/DSCF2619.jpg)
(http://i261.photobucket.com/albums/ii63/john970s0/DSCF2607.jpg)
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Mate they look fantastic. Is that bronze or brass?
According to MY Guru, bronze is a little easier to cast than brass....
Actually MY Guru :med: is the same guy as YOUR Guru :med: ..... young fella goes by the name of Rob W....... talks a lot but he knows his stuff...... :bow: :bow: :bow:
(he he ... sorry Rob...)
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Looking great John :thumbup:
I have had the pleasure to have a look at this engine ,,,,,,,and its a big one :bow: :D
Cheers Rob T ,,,,,,, :lol:
Regards Rob
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Hi
Been buisy machining the valve covers we cast last week.
Decided to mill our initials in to the faces my mate is called Turner so his is easy.
My M is not so straight forward i think it is going to hit the mark what do you think
(http://i261.photobucket.com/albums/ii63/john970s0/P5080030.jpg)
(http://i261.photobucket.com/albums/ii63/john970s0/P5080029.jpg)
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Hi John :wave:
:bow: :bow: :bow: :bow: the valve covers are going to look great with your initial on , nice bit of detail work :clap: :clap: :clap:
Regards Rob
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A bit of the old ball slot drill work you can't beat them for a bit of bling :thumbup:
Great work and a very interesting thread
Thanks
Stew
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Cast 2 ecentric housings today
(http://i261.photobucket.com/albums/ii63/john970s0/P5100034.jpg)
Machined one of the valve chest covers
(http://i261.photobucket.com/albums/ii63/john970s0/P5100033.jpg)
On a more serious note
We scaret the s$£"e out of ourselves .
We poured the bronze in to the mould that went well , the bronze that was left we poured in to a angle iron ingot mould.
The mould was cold and must have had a drop of water in it , a loud poping nouse was followed by a shower of molten metal.
We both escaped injury more or less , have a look at my mates face screen .
Without this the results would have been devistating . Some very serious lessons have been learned
(http://i261.photobucket.com/albums/ii63/john970s0/P5100036.jpg)
(http://i261.photobucket.com/albums/ii63/john970s0/P5100035.jpg)
John
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Hi John
I a pleased you and Walter are OK ,,,,,,,,, and no real harm was done , i have gone through the same thing .It only takes a very small amount of moisture to come in contact with molten metal to cause a very violent reaction Its good you posted the photos of the face shield ,
LET THIS BE A WARNING TO ANYONE CASTING , WATER AND MOLTEN METAL DO NOT MIX , MAKE SURE ,ALL FOUNDRY TOOLS / INGOT MOULDS / LADLES/ DROSS SKIMMERS /DEGASSING TOOLS ARE PREHEATED AND FREE FROM MOISTURE BEFORE COMING INTO CONTACT WITH ANY MOLTEN METAL AND WERE THE CORRECT PPE
Casting look great John :clap: :clap: :clap: :clap: :clap: :clap: looking forward to seeing them all machined up ,, Your initial turned out great :thumbup:
Regards Rob
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Hi
Put some more casting video up
Sorry about the voice over (must be the wine)
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Great stuff very informative :thumbup:
What no bacon butties, must be on a diet :D
Thanks for showing
Stew
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Great stuff very informative ..... Thanks for showing
+1
What no bacon butties, must be on a diet
Well, this being breakfast time (although unfortunately with no fry-up) .... at the very end, where the castings were being dis-interred with what looked like a BBQ/carving fork, I couldn't help thinking they looked like a couple of fried eggs and a square of Ulster Fry or fried bread? :coffee:
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Just love your vids. Very educational and inspiring. :clap:
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Hi all. Very nice videos. I have a doubt. What did you spray on the drag and cope? It seem graphite. isn't it? Please tell us what is it, and how did you do.
Thanks for sharing your experiences.
ToniTD1490
Spain
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Hi
Powderd graphite suspended in brake cleaner
It gives the mould a nice hard skin (advice from master caster Rob Wilson)
John
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Machined the ecentric straps we cast last week.
First time i have used a rotary table very clever stuff
(http://i261.photobucket.com/albums/ii63/john970s0/P5290119.jpg)
(http://i261.photobucket.com/albums/ii63/john970s0/P5290121.jpg)
First time i have made 2 things the same size :) :) :) :)
(http://i261.photobucket.com/albums/ii63/john970s0/P5290125.jpg)
That is a 6 inch chuck i like big engines
John
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Hi John
They turned out great :bow: :bow: :bow: :bow: spot on for a first time using a R/T :thumbup:
Regards Rob
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Nice work! Most people just try turning a few "roundy" things their first try with an R/T.
Dean
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VERY nicely done for a first go! :clap: :thumbup:
David D
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Hi
Got some more machining done on the ecentric straps
(http://i261.photobucket.com/albums/ii63/john970s0/P5300137.jpg)
Found that face plate at a car boot sale today got it for 20 pence
(http://i261.photobucket.com/albums/ii63/john970s0/P5300134.jpg)
(http://i261.photobucket.com/albums/ii63/john970s0/P5300150.jpg)
Left hand thread makes setting rod lengths a doddle
(http://i261.photobucket.com/albums/ii63/john970s0/P5300145.jpg)
I think it would be a good idea to do a project log on this engine if anyone is interested
It is a Hasbrouck No 8 V twin
John
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Hi John :clap: :clap: :clap:
See you have had the LH die out :) ,,,,,,,,,,,, A build log would be GOOD to see :thumbup:
Regards Rob
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Hi John :clap: :clap: :clap:
See you have had the LH die out :) ,,,,,,,,,,,, A build log would be GOOD to see :thumbup:
Regards Rob
Good thinking Rob! :thumbup:
I thought that, every time I read an update..... Somehow, never got around to asking! ::)
Pleeese! :D
David D
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Hi
Powderd graphite suspended in brake cleaner
It gives the mould a nice hard skin (advice from master caster Rob Wilson)
John
Sorry to resurrect this old thread, but I was just reading some of the great stuff in the metalworking archives, including this one when I saw this one little line and it jogged a memory of something pretty frightening about the hazards of brake cleaner when heated. I managed to track down the reference to the warning here:
http://www.brewracingframes.com/id75.htm
Substitute:
The solvent I've seen for graphite mold blacking in most books on casting is just household isopropyl alcohol (rubbing alcohol) and is probably cheaper than brake cleaner anyway.
Again, apologies, but thought this was important to bring up in case someone else tries it.
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:wave:Hi vtsteam, Well done for posting, that is a scary story and something that anyone could end up doing as the guy who it happened to stated. We are so bombarded with tiny small print warnings on everything from a bottle of water up over, really covering the producers legally more than information for thr user jjudging by the size of prnt, it has had the effect that everyone ignores it all and the really important warnings get swamped within the nanny state stuff.
Maybe it would be worth forum members making a post with a list of REAL serious and likely shop hazards for members to check down and see without reading reams of tiny print on labels, a list of what does reallymatterfromthe horses mouth so to speak.
Thanks for posting ,Cheers Mick.