A bit of casting

[Rob.Wilson]

Hi Lads  

Its been a wile since i have had my furnace fired up  ,,,5 months going by the RW engine post    ,,, Well i have being doing a bit casting today  

I have a couple of jobs on for lads on here ,, First up is a water jacket  ,, a few shots of the pattens being made so you can see how they are built up .




The core box


Now with a bit of slap on .




Making the core.




The two harfs stuck to getter after baking


A few shots of the mould

Burning of the mould wash ,,, home blend of traditional herbs and spices .


Core in place


All ready to go


Bearings warming up in the exhaust , so they are pre warmed for the pot .


Pored


Looking good this side


Hole this side   ,, cold shut   ,,,,,,,, ooooooops    



O there goes the timer bell on the cooker ,,,, new set of cores ready  


Back soon Rob  

[Powder Keg]

That is Awesome!!! I have never done anything with Cores yet. What is "mold wash" I have never heard of it before. I've had my share of flops. 

[Jasonb]

Looking good Rob, I know a man who will be happy with that hopper, shame it won't hold water, maybe he's got a bit of JB Weld or his prefered Milliput knocking about

Are you going to do your engine with a similar hopper ?

Jason

[Bogstandard]

Methinks Jason is spot on.

I was only speaking to Rob the other day on Skype, and I was shown the fantastic patterns then. Then my thoughts kicked in, and the drooling from the mouth corners started.

Rob had already pre warned me about the failures at the beginning, so knowing what a bit of a perfectionist Rob is, I am sure all will come good in the end.

So this post will spur me on to get all my backlogs finished, allowing me get onto the R&B engine.

 


Bogs

[Stilldrillin]

Really classy work. 

Better luck next cast, Rob! 

David D

[Bluechip]

Nice one Rob, ..... didn't know you did woodturning ... Myford Maestro ??

I had a Coronet CMB500, although it often had the slot mortiser on it..

Did a good few bowls and the like, but never really mastered bead turning with the skew-chisel.
Usually landed up practising pole-vaulting ... 

Never tried to turn my pyjamas though ....( pic #1 ) 

I'm off .....

Dave BC

[Rob.Wilson]

Cheer LADS 


Wes ,,"mold wash"  is a coating usually sprayed onto the cavity ,, it helps the molten metal flow across the surface of the mold , fills in the pores of the sand giving a better finish and stops the sand sticking to the casting .


Jason ,, milliput ,, wonder if you can get it in bronze colour  do you reckon John would notice    ,, No,, i am doing the water jacket a different way     


Hi David ,,,,,,,,, next time    ,is coming up


Hi Dave ,BC  ,,, i get by  the skew     that reminds me i have a couple of parts to cast for the myford wood lathe


Rob 

[Jasonb]

Jason ,, milliput ,, wonder if you can get it in bronze colour  do you reckon John would notice    ,, No,, i am doing the water jacket a different way     

Teracotta mixed with a lot of white and you may get away with it or just use one part of the yellow/grey one though it may stay a bit sticky

Fill it with braze or silver solder a bit of material into the hole, spray it with a coat of primer before you give it to Bogs and he'll never know

J

[Rob.Wilson]

Well John no cigars this time  


You no its not worked when you you see this   ,,, mold split  
 

But the new gating and a tad hotter pore did fix the cold shut problem on the thin section of the casting  



And the fun side  



I can count on one hand the times i have had a mould split .Not to worry tomorrows another day ,, I have had a fun day   ,, my new molding flasks work a treat , and i am fit to cast  


Cheers Rob ,, time for a large one  

[Bogstandard]

Well Rob, you did reckon on about four pours before you really get it singing. No worries, you'll get it cracked.

BTW Rob, if you see my Skype on green, could you give me a call.

Jason, it isn't just me Rob has to fool, it is Bandit as well, he can sniff bullsh and woffle at two hundred yards, and he's got real teeth to get his point across, whereas mine only get inserted when royalty calls.
Getting into my yard is easy, getting out again is the problem.

Bogs

[Rob.Wilson]

Hi John

That one would have been just the job if the mould had not bust     ,,,, but were is the fun in getting it right fist time   


Rob 

[doubleboost]

Looking good Rob

[Stilldrillin]

Oh BUGGA! 

Well Rob..... I guess you must need the extra practice......   

As the man said...... Better luck next cast! 

David D

[Rob.Wilson]

Hi David

BUGGA was not the word i used  

At least your flywheels will be easy  


Rob  

[Powder Keg]

So whats it made of? Mold wash? 

[Rob.Wilson]

Don't  tell anyone cos its a secret ,Wes  

 a flammable liquid , i use brake/carb cleaner ,,, something light that burn easy ,, graphite powder ,, you have to keep giving it a shake as the graphite settles out and a  bit treacle/molasses .   the brake cleaner carries the graphite powder so it can be spayed and when set a fire the molasses is baked on  sticking the graphite to the surface . Also the burning off of the brake cleaner skin dries the mould .

Just something i came up with a bit trial and error   works well for me ,,,, Great on cast iron ,, gives the casting a nice black finish

Rob    

Edit ,, forgot to say i use one of those pump up sprayer to apply it with .

[Powder Keg]

Thanks Rob I'll have to give it a try. do you bake your Cores with Molasses also? I have some Sodium Silicate to try out. Just need more time

[Rob.Wilson]

I do Wes 

This is the mix i use


10 parts silica sand  ,,,,,DRY

5 parts  moulding sand ,,,,,DRY

1 part  core binder ,,,, which is a type of corn starch i think

Mix above dry

Temper with molasses water  or core oil (linseed oil ) 

Core oil dose give a better core , but stinks when baking .

Rob

[Artie]

his sound about right?

..... mixture 50/50% zircon flour and graphite stirred into either alcohol.......

 

[Dean W]

It sure is gonna be pretty on the next pour, Rob.   
Your posts are a real pleasure, always!  It's good for me to see a persistent fellow at work, too.   
Inspirational, and all that, seeing how much work goes into each of these pours, and you just seem
to make light of it when you have a little (or big) catastrophe.  You just keep at it like you're killin' snakes! 

Now, is that "B" for Bogs, or for Bandit?    

 

Dean

[Bogstandard]

The first one Dean, but because it is on two sides, it could mean both of us, we are a team after all.

But unlike Rob's main casting, where he has cast his name onto it, I hope to have a brass plate engraved up for mine, 'Bog's & Bandit Manufacturing Co.' or something to that effect.

All you people can't feel the expectations I am feeling at this time.

To have Rob, in my eyes a master caster, making something for little ol' me, to finish off my engine to perfection and uniqueness, is truly mind blowing. Beyond my wildest dreams. I only hope that the rest of the engine will turn out as well as this will, and be able to do this piece justice.

What all you onlookers don't realise is the amount of work that Rob has put into this one item.

From my C-o-C's that I sent him, with a roughie set of dimensions and ideas, he sent me back some fantastic CAD drawings (some even rotated) showing what the finished article would be like. It was truly like being at a birth, a lump came to my throat just looking at them.

What the original drawing looks like, showing the copper tube cooling jacket





My measly offerings




And What Rob came up with, click pic to see.




Bogs

[Rob.Wilson]

Cheers Dean

I always try and  look for the positive , there is always something to learn from a mishap      and i think its good to show that its not all plain sailing ,even if it gets a laugh 


I am going a different rout as regards the water jacket  ,,, something like this ,,, still not quiet there

 


Two cores ,, could be done with one core and a liner  ,,,,,,,,,,  but two will be more fun 


Rob

[Bogstandard]

I had forgotten you have yet to make patterns and cast your cylinder Rob.

So it is just common sense that you build your water jacket into it as it is being made.

So another unique engine.


John

[Dean W]

It's quite a leap from Bog's first drawing to the 360° animation.  I mean, Rob filled in a lot of blanks
and came up with a unique and interesting original.  And then, the casting itself...
Quite a good show.  I can see why you're excited about it, John!

[Rob.Wilson]

Hi Chaps 

Here are a few photos of some of the other  patterns  i hope to get cast over the weekend




And a door and frame for the stand i made for the wood lathe ,,covers the hole thats needed in the side to gain access for the belt change





Looks like i will have the furnace running a fare bit this weekend 


  Rob