MadModder

The Shop => Metal Stuff => Topic started by: inthesticks on June 11, 2016, 10:03:41 PM

Title: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 11, 2016, 10:03:41 PM
I started this build on another forum. I quickly found I was wasting time with a "your new so you don't know anything" attitude. I quikly cut my losses and left.

This is a Dave Gingery style crucible furnace. I chose this style for two reasons. The body lifts out of the way so after skimming the dross, the crucible goes directly from furnace to pouring resulting in less heat loss from handling and greater safety again from less handling.

The furnace body is 16" in diameter by 24" high, cut from a discarded water press. tank. Max. aluminum capacity 30 lbs. in steel crucible. Bronze or iron 24 lbs. in #8 clay graphite crucible, #10 will fit but I don't plan to cast much iron.

I am planning on two types of burners. A Reil type atmospheric burner to melt aluminum and a Lionel Oliver type waste motor oil burner for high temp. metals or when my barrel is full.

Plan Of Action:
1. Build shell and shell attachments.
2. Build carriage and lifting mechanism.
3. Install refactories.
4. Build burners and day use oil tank.
5. Test furnace performance.

Enough talk, on with the build  :clap:. The first photo is the shell cut from water tank, I have a # of projects planned over the next few years so a steel delivery was in order. The 3rd pic is the bottom section with drain hole cut. The last pic. is the burner port cut and ready for burner mount.

I will compleat burner mount and post tomorrow.

Cheers All
CB
 
Title: Re: Dual Fuel Gingery Type Furnace
Post by: SwarfnStuff on June 12, 2016, 01:15:19 AM
So far so good,CB. I shall watch with interest as building a furnace smaller than your project is on my to do list. I was given about 10kg of brass taps a while back plus I also have some aluminium from various sources to play with.
      I shall be starting with a 1litre bucket and finding suitable refractory material within easy distance from home is problematical so that will be a home brew I think. The occasional brass melt dictates choice somewhat but I have found some hi temp mortar sold for pizza oven builds that has a 1000C rating nearby so am starting with that and perlite. Not sure whether to add sand a mortar already contains aggregates, (according to the bag 0-2mm).
      One of my neighbours seems to amass more than a few Al cans that I could also get. There appears to be some discussion on the source of much disinformation regarding the worth or lack thereof in smelting cans. But hey! they're free.

Regards,
John B
Title: Re: Dual Fuel Gingery Type Furnace
Post by: DavidA on June 12, 2016, 09:59:08 AM
John,

FYI, it hakes about 110 coke cans to make up 1 Kilo. And that includes the paint etc.

No idea how much usable metal you get from that.

Dave.
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 12, 2016, 11:10:43 AM
Hi John B. I have no experiance with peralite but I am told it's ok for aluminum but will break down for the higher temp. metals. I assume your mixing it with the 1000*C refractory if you put a fireclay and sand mix hotface over it, it should give you some protection.

Most peoples objection to pop cans is how thin they are. Heavy oxidation producing lots of dross and resulting melt loss will occur. A very tight crush on the cans will help a bit.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: shipto on June 12, 2016, 04:45:34 PM
I used perlite on my elelctric furnace  and I used a mix that I cant actually remember proportions at the moment but it was perlite, cat litter, sand and cement but to make the lid which I wanted a little lighter I added extra perlite while taking a little sand and cat litter away with the result that it was indeed lighter but it seems that it is breaking down quicker than the body of the furnace.
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 12, 2016, 07:03:12 PM
Hello everyone. That seems to be in agreement with what I have read SHIPTO.

Finished the burner port and mount today. The first pic. shows the assemblies ready to install and a 1 1/4" burner pipe to verify clearances. This represents the largest burner I plan to use. The 2nd pic. is the port extention installed. The 3rd pic is the burner adjustment spud (thats what I call it, may not be correct term) bolted in place. 4th pic. is burner pipe in operating position. The last pic. is the burner pipe pushed all the way in to check side wall clearance. Refractory will be 3.5" thick, so the 4" I measured is just about right taking into consideration the burner flare. The burner spud will also allow 10* of adjustment in any direction up, down or sideways.

Cheers All :beer:
CB
 
Title: Re: Dual Fuel Gingery Type Furnace
Post by: SwarfnStuff on June 13, 2016, 03:22:19 AM
At the moment it's all experimental with the refractory mix. Basically I'm making plinth blocks to test.
    Today I tried a 5 parts perlite to 1 part Mortar. A few days to dry out and I shall hit it with the torch and see what happens. The 4:1 mix seemed to take the torch ok.
       I do have thoughts of some form of hot face perhaps with clay or might start with straight hi temp mortar. BUT, that's way down the track. The more I read on the web the more confusing it seems.
John B
Title: Re: Dual Fuel Gingery Type Furnace
Post by: nrml on June 13, 2016, 09:56:19 AM
what you are building looks more substantial than the average trashcan forge. Why not spend a bit on ceramic fibre insulation and have the ability to melt cast iron if you want to. Ironman has demonstrated that this is definitely possible. 
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 13, 2016, 10:23:31 AM
I agree John B there is alot of confusing and contradictory information out there. Pearlite, concrete morter and vermiculite seem to be ok for aluminum but breakdown into fluxes at higher temps. which will damage your crucibles your furnace lining and effect your melt. Years ago I operated the power plant at Orenda Aerospace in Mississauga, when the plant was decomissioned I got 2 1/2 boxes of A P Green's G-26 insulating firebrick heavily used in industry. I will be installing this in the bottom 2 sections with a 1" high alumina hotface. The top will recieve a castable insulating refractory with a hotface. Some of these products are quite expensive. For a small furnace occasionally melting lower temp. metals I would go with the less expensive options too.

I have lots of fine sand and white clay on my property. I want to try this material for my green sand and once I test the refractory properties of the clay maybe evan as a refractory.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 13, 2016, 10:30:00 AM
I agree NRML mineral wool is a fantastic material however I would hate to waste 2 1/2 boxes of high quality industry proven insulating firebrick. See above post.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 14, 2016, 06:23:59 PM
Hello again;

Following is the last couple days work. In 1st pic. are 6 alignment tabs hammered out of junk box brackets and the lifting bolts and attachments. I am using 3 1/2" shoulder bolts to extend the measurment between the lifting arms by 4". This will allow a 20" shell if I decide to play with a larger furnace in future and allow me to use the same carriage and lifting mechanism. Pics 4,5 and 6 are the parts and assembled preheat rack. Essentially the shell is complete. The bottom lip of middle section will get a refractory support ring and once the lid lift is complete I can fit it to the lid then the rack will get a finished edge around it's circumferance to avoid snags.

Break time, got to clean up the mess I've made so far and catch up on chores.  :whip:

Cheers All  :beer:

PS: I know the welding could be better, but heck I'm getting old and shaky.
Title: Re: Dual Fuel Gingery Type Furnace
Post by: SwarfnStuff on June 15, 2016, 02:46:26 AM
 OOPS!   :doh:
      Just re-read my earlier post (12 June 2016) and I am NOT using a 1 litre bucket. That would be ridiculously small. I meant to type that I was starting with a 15 litre bucket. Slightly larger.   :Doh:
Title: Re: Dual Fuel Gingery Type Furnace
Post by: DMIOM on June 15, 2016, 03:47:24 AM
hi CB - just a suggestion : the preheat rack (pic 18) has the raw edge of the mesh which is likely to catch either skin or clothes - you might want to consider tacking say a 1/4" rod round the outside?

Dave
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 15, 2016, 09:06:48 AM
Hello John B
Ha ha yes 15 liters sounds more usefull  :clap:

Hello Dmion
Please reread the post. I address this in the last line of the main body of the post. The edge can't be finished untill I determine where the lid lift struts will cross the edge of the rack. It will require trimming in 2 locations before the finished edge can be applied.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: DMIOM on June 16, 2016, 04:39:36 AM
.....
Hello Dmion
Please reread the post. I address this in the last line of the main body of the post. The edge can't be finished untill I determine where the lid lift struts will cross the edge of the rack. It will require trimming in 2 locations before the finished edge can be applied.

Cheers
CB

apologies CB, I'd missed that.     :doh:

Dave
Title: Re: Dual Fuel Gingery Type Furnace
Post by: Toolshed on June 17, 2016, 03:03:28 PM
Not sure if I already touted the AlloyAvenue website here.  Those guys know their sh!t when it comes to making furnaces and they are always helpful to new folks!  They helped me get from ZERO to casting....

From what I read over there, don't even bother with the prelite/grog....You'll be crying soon after.

ALSO, there are a lot of Canadian posters who might be able to help source more local things for you.  Though no one within a days drive of you....

https://www.google.com/maps/d/viewer?ll=59.623325%2C-54.140625&spn=56.202277%2C214.277344&msa=0&mid=zHlqXRJDUiXo.kWP86wuXUV-o
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 17, 2016, 03:44:30 PM
Hey TOOSHED,

Yes I have been on Alloy Avenue I found I was spinning my wheels in loose sand and left. All of Ontario is within a days drive of me except for the area west of Thunder Bay  to the Manitoba border. An early summer road trip to the Toronto area should fix me up with the harder to find materials I need.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 19, 2016, 08:39:30 PM
Hello all;

I managed to get in a couple of afternoons in the shop, fixed one screw-up and built the mobile base for the carriage.

Here are some pics.
1. The angle iron and deck cut, mitered and clamped ready to weld.
2. The casters and mounts ready to install. Didn't have matched set so, Heavy iron core swivels on furnace end, standerd duty on light end.
3. Casters installed, all welded up.
4. Crucible failure catch pan slide supports installed.
5. And just to try it out to see how it fits.

Cheers all :beer:
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 20, 2016, 07:34:51 PM
Hello all;

Did not do much today, high winds nocking power out all afternoon. Got the ingot mould/crucible failure catch pan welded and fitted. This ones for aliminum
I will make a pan lined with refractory or a couple of inches of sand for the occassional iron melt. Its a good idea but its not my idea I have seen at least 2 other builders use this type of setup.

Here are some pictures.

Cheers All
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: Homebrewer on June 20, 2016, 08:38:17 PM
Are you planning to allow the melted metal to drop right through the bottom of the furnace, directly into the ingot mold?

Sent from my SAMSUNG-SM-G900A using Tapatalk

Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 20, 2016, 09:32:25 PM
LillyHillBrewer I guess your new to this, the reason its a good idea is it gives the mould a double function in the case of aluminum, you store it under the furnace so if you have a crucible failure and they do happen, your crucible will empty through the drain hole into the ingot mold rather than onto the ground.If your casting ingots its a simple matter to slide it out when you are ready to pour.

With iron were crucible falures can be so much more dangerous A refractory lined or partly sand filled pan will catch the contents of your crucible. You may be thinking of a direct melt furnace that some builders use to melt scrap aluminum they work but are highly oxidizing and are used mainly to reduce scrap to ingots, to many contaminants for direct casting.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: Homebrewer on June 20, 2016, 11:06:56 PM
You're right; I am new.  Been reading about all this for a few months and trying to learn.  What you described makes perfect sense.  Thanks!

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Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 21, 2016, 12:20:45 PM
Hello;

Here's what I should have finished yesterday till the power bumps screwed me up. Bolted the bottom section to deck using 3/8 X 1" NC bolts and lock washers.

Here's a couple of pics. On to the lift assemblies.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: Toolshed on June 22, 2016, 10:54:36 AM
Ok that is MAJOR NICE WORK there man!!!!  I wish we were neighbors!!!!!!!

 :beer:
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 22, 2016, 06:46:17 PM
Your to kind TOOLSHED, thank you.

I managed to get a couple of hrs. in the shop this afternoon. Started on the lifting arch which both lifting assemblies will attach too.

Here are the pictures.
1. Arch deck mounts welded and drilled to accept 1/2 X 4" bolts.
2. A salvaged greasable bushing mandrel with pully, to be used as top lift pully for cable lift.
3.Arch cut mitered and welded with mandrel fitted to top of arch.
4.Arch installed in deck mounts.
5.How it looks so far.

Cheers all
CB
 
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 23, 2016, 07:48:27 PM
Hello all;

Managed to get a full afternoon in the shop today sunny and cool great working weather. Today I built the arch braces and mounted the lift winch. In the first 2 pictures are the finished braces and the braces bolted to the arch and deck with (8) 3/8 X 3/4" NC bolts. The next picture is the winch plate bolted to the braces with (4) 3/8 X 3/4" NC bolts. Below is the worm winch I will install. It is rated for 2000 lbs. certainly overkill but I had 2 on the shelf just waiting for a project.I also had 2 smaller boat type winches but these are not recommended for this application. The worm winch will lock in any position when you release the handle without fiddling with pawls. in the last 2 pictures are 2 views of the winch mounted with (3) 1/2 X 1" NC bolts.

Till next time.
Cheers All
CB
 
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 24, 2016, 05:58:20 PM
Hello again;

Didn't get alot done today, the old body isn't what it was anymore. Fitted 25' of cable to the winch. Cut and welded up lift guide. Checked guide fit to arch and total lift. 2nd picture at bottom, 3rd picture at top of lift, total travel 22"  :thumbup:

Cheers All Its Friday  :beer:
CB


 
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 26, 2016, 04:26:21 PM
Puttered around in the shop last couple days, fitted lift arms and lid lift guide to body lift guide. reassembled the works and made some adjustments to get the right fit. For thoughs not familiar with this type of lift it is really 2 lifts working with each other. The main body lift will lift both the body and lid and will only be used when you are ready to pour. The lid lift will be activated with a foot pedal allowing you to swing the lid away from you and the top of the furnace allowing you to check temperature or add metal to the melt. The lid lift rod is guided by a tube welded to the main body lift.

Hope these pictures help and will become clearer with the building of the lid lift next.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 27, 2016, 05:54:22 PM
Hello fellow modders;

Managed a couple of hrs. in the shop today. Built the foot pedal lid lift and welded to deck.
The pictures speak for them selves.

Cheers all
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: DavidA on June 28, 2016, 06:24:13 AM
..Didn't get alot done today, the old body isn't what it was anymore...

I know the feeling.  But you are making steady progress.

Just looking down at the concrete flags (pavers) I have to lay today before the rain comes. When it does rain I can go work in the shed on some project or other.
I still have to start my furnace build.

Dave.

Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 28, 2016, 02:11:50 PM
Hello Dave Yes with me the muscles are willing but the joints complain all the time. Patio stones are always a good workout. Glad to hear your going to build a furnace ,I always look forward to seeing the new ideas people come up with. :clap:

Did some work this morning. I have been trying to figure out a way of locking the lid lift in the raised and lowered position, not really neccessary with a steady foot on the pedal but for conveneance and safety it was sticking in the back of my mind. A dig through my magic junk box came up with a spring loaded plunger and a flat bar from a broken quik clamp. The pictures show what I came up with .

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 28, 2016, 06:44:50 PM
Hello again;

Managed to complete the lid lift this afternoon. The first 2 pictures show the struts, lift rod and method of attachment.1 more day finishing off the cosmetics and this stage is basically done. Next refractories and burners.

It was so nice out today I decided to take her out for pics. :D

Cheers All
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on June 29, 2016, 06:25:59 PM
Hello Modders;

Managed a couple hrs. in the shop today, made some adjustments to the body and rolled and welded finish ring on preheat rack. Here's a couple pictures.
Cheers All
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: RobWilson on June 30, 2016, 11:55:26 AM
Coming along very nicely CB  :clap: :clap: :clap: :clap:


I am looking forward to seeing the first melt  :thumbup:


Rob
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 01, 2016, 02:14:47 PM
Thank you Rob.
I still have to make a trip down south for refractory supplies. In the mean time I am trying to modify a surplus fan I have to get the outlet pressure I am looking for. If unsuccessful I have a spare 3/4 HP dust collector fan that will do the trick. As this is a cost to the bottom line of operating the furnace I would rather not go oversized here.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 01, 2016, 08:09:32 PM
Well looks like I made some progress on that fan. The 2 old salvaged fans I had in storage have squirrel cage wheels, good for volume not for pressure and the motor only draws 1.5 amps at 120V. I have a couple nice motors drawing 3.5 amps-1/4 HP which would be preffered. Using D. Gingery's book "How To Design And Build Centrifugal Fans" as a guide I made and installed 4 radial type blades into the original fan runner. These should increase pressure without impacting volume. I also made a adapting plate for the new motor. After reassembly I started it up and found the outlet pressure is 3-4 times previous. This was determined by simple hand over outlet press. I will eventually confirm this with a manometer I am looking for at least 3"s water column. The old fan was no more than 1".
This fan will ruffle my T-shirt standing 16' away. I will use this on a propane burner and and if it puts out enough to burn oil all the better.I was concerned about vibration from imbalance But it ended up running quietly and vibration free a little luck and the small diameter of the runner no dought.
Pictures 5 and 6 is the damper I installed to control the inlet.

Cheers
CB

Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 05, 2016, 05:23:33 PM
Hello All

Haven't done to much on the furnace lately, been mostly aquiring materials. Finally made that trip to the Toronto area for refractory material. In the first picture are the materials I now have. I hope this will do for at least 3 projects, the only thing missing is Durablanket 2600 which the supplier did not have in stock, no problem its light enough to ship anytime I plan to use it for a future forge project. The products from left to right, 2 pails of 3000* firebrick morter, 5 bags of castable 3200* hotface, 3 bags of fireclay, on top 2 1/2 boxes of A P Green G-26 insulating firebrick and 5 bags of Bentonite clay for making green sand, 3 bags of southern recommended for aluminum and 2 bags of western recommended for the heavier metals brass and iron.

The second picture are the popane tanks on the pad I cast a few years ago for this purpose. The plan is to pull from the 2 30# tanks. They will be tide in to the 100# tank with a switch over valve in case I run out in the middle of a melt or if I need higher press on a cool day. I went with the 2 smaller tanks for regular use because they will be easeir and more conveniant to transport for refilling. Some would say thats alot of expence for a hobby but that is not their only intended use. By far the majority of power outages around here only last 2 or 3 hours, usually a tree on the line somewhere. I have a small propane generater that I want to use in these cases as opposed to my large gas fired generater which is a bit of a waste if all you need is lights, electronics and a cup of coffee for a couple hrs. I'll revisit this when my connections and piping are all done.

Almost forgot I also picked up a clay graghite #8A crucible to try out an iron melt or two I hope. :clap:

Cheers Modders
CB

Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 06, 2016, 08:08:21 PM
Hello all, soggy wet day out there today but still managed to complete the waste engine oil day tank. The tank when in use will hang from my garage eave from a pulley and lift rope. The hieght will be 10' giving about 4 PSI at the burner (borrowed idea). The tank will be heated by a 300 watt KATS magnetic block heater (my idea) Temp will be checked periodically with a laser pointer temperature gun. The oil discharge pipe extends 3" into the tank to act as a stand pipe and prevent the krud settling out of the oil from leaving the tank. The bottom of the oil level site tube is 1/4" above the top of the stand pipe indicating the need for a refill. The cap on the fill pipe has a channel drilled from underneath to allow the tank to breath and prevent a vacuum. The last picture is the tank complete minus the oil hose and a black paint job. To soggy to hang and paint outside today.

Cheers Modders
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: DavidA on July 07, 2016, 07:28:22 AM
May I suggest an improvement to heating.

If you add a small (say 1 Litre) tank between your main tank and the outlet to the furnace, you could just heat this.
It would heat the oil in it much quicker than if you heat the whole tank. An, of course, as the hot oil is used,cooler oils will replace it and in it's turn be heated.

Just an idea. I this sometimes used by the SVO people who need to heat up cold veggie oil for their car fuel pumps.

Dave.
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 07, 2016, 10:31:36 AM
Thank you for the imput Dave;

A good suggestion same idea as a flash water heater as opposed to heating a large storage tank. I don't plan on burning alot of WMO just my own production from yard equipment and vehicles. I now have a full 55 gallon barrel and I don't want to give up the space for another.That said the day tank will only hold 3-4 usefull gallons of oil this is only one large melt or two small ones. My main concern with heating is to get good flow to the burner and promote better seperation of solids at the supply tank and of course raising the temp. will improve combustion. I could complicate the system by adding an oil filter which would require pressurizing the tank bringing my shop compresser into the picture. A small heater like you suggest after the filter would be ideal and certainlly the way to go if oil was my main fuel.
The magnetic block heater is a quik and easy solution for occasional use and at 300 watts I will not be reaching temperatures higher than you would expect in  engine block heating.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 07, 2016, 10:28:03 PM
Didn't do much today, should have been out cutting 5 acres of lawn but still to wet to cut grass, so puttered around in the shop instead. Built a transition piece for the burner fan, built a rough and dirty manometer to check static press. The first picture is the set up. The second picture is the manometer with imput connected but fan off. The third picture is the manometer with fan on and outlet plugged. the reading is the total difference between the two legs, I get roughly 3.1-3.2" water column which is plenty for propane. We will have to see how it handles oil. I can gain a bit sealing the transition piece but not much.

PS: Very humid day today after that rain, reading will also improve some on a less humid day.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 09, 2016, 12:24:40 PM
This wet weather persists, haven't got outside to hang oil tank but I got it painted up, installed a valve on the outlet so I can disconnect hose for storage. The hose is 24' of one half of an old oxy-acetylene hose I had. I installed quik connectors at both ends for conveniance and so I am not dripping oil all over the place when storing hose.The other item in the picture is the pulley assembly for hanging the tank, maybe tomorrow.

Working on the dual burner maybe done today.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: Homebrewer on July 09, 2016, 03:16:45 PM
That looks great!

Could you do a separate, quick thread on the mamometer perhaps?  I'm sure a couple of us are a little curious about that as well.


Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 10, 2016, 01:56:37 AM
Thanks for your interest LibbyHillBrewer. The manometer I put together is pretty rough, I just wanted to verify I was in the ballpark on this fan. If I build a proper one in the future I will certainly do a write up on it. In the meantime if your interested I made up a PDF which is  from D. Gingery's book "How To Design @ Build Centrifugal Fans For The Home Shop". It will show you how to build one and explain the readings.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 10, 2016, 02:47:49 AM
Well I did manage to finish the dual fuel burner today. The design is virtually the same as Lionel Oliver's "Hot Shot"(1st picture). Mine is one size larger 1 1/4" instead of 1" burner pipe he also used 1/8" black iron pipe for oil injection I used 1/4" brake line tube, and total length is about 3" longer. In a later version he extends the oil pipe to the end of the burner pipe which I did here. I did not have a 2" nipple long enough for the blower pipe and my pipe dies stop at 1 1/2" so I welded 1/2 a close nipple to the end of a 2" pipe. Hey!! it worked :clap:. I resisted welding the oil delivery pipe to the blower pipe, threading it instead so that if I need to make changes in the future, it can all be dismantled. Both oil and gas have needle valves for positive control and quik connect fittings.

Cheers Modders  :beer:
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: DavidA on July 10, 2016, 06:43:26 AM
 On manometers.

Many years ago, when I was working in the maintenance dept of our local chicken processing factory, one of our gas fired boilers developed a problem. It would start ok, but when it tried to switch from start to run it just cut out. The electrician couldn't find any electrical problems. I suspected the gas supply. So I made up a crude manometer using about ten foot of 10mm bore clear plastic pipe. I fixed it to a length of plank so that it formed an elongated 'U', added water until the water level was about half way up the pipe (naturally on both sides of the 'U'), and connected one end of the pipe to a spigot on the side of the gas supply pipe.
A mark was made on the board coinciding with the level of the water.

And the boiler was switched on.

At first the gas pressure showed, as expected, a positive pressure, not much, about 2" of water if I remember correctly.  But when the system tried to go to 'run' the pressure dropped back past the original mark. In other words it was, briefly, pulling a slight vacuum.  And there was the problem.

A gas boiler system must never have a negative pressure in it as there is the potential to draw in air. This can lead to an explosive gas/air mix. So the electronics detected the negative pressure and shut the system down.

For very low pressure measurement, manometers are simple, rugged and virtually fool proof. There is nothing to go wrong.

Dave.
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 10, 2016, 10:20:18 AM
Did you determine why your gas was shuting down. Did you connect to the pilot startup line or your main supply line. Sounds to me like your pilot flame was not lighting off, after a set time on your fireye (or other make) flame senser the startup would be shut down. A properly designed system has more than one check valve in adittion to your control valves and unless you loose press. on your supply side (line break) you would not be sucking air into the system.At startup you supply gas to your pilot. After a predetermined time if the fireye does not detect a flame the system shuts down. The valves sudenlly closing and the momentum of the remaining gas in the pilot supply line could momentarily produce a negative press. But you would not be in danger of sucking air into the lines.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: DavidA on July 10, 2016, 01:40:38 PM
The problem was handed over to the boiler supplier.

I had nothing else to do with it, but gatherer form later conversations that it was due to the bore of the pipes supplying the gas. It seems they were not really big enough and when the run stage blowers came on the supply briefly dropped below a critical level. A section of bigger bore pipe was fitted leading up to the boiler and the problem went away.

Dave.
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 10, 2016, 07:52:11 PM
Didn't do a heck of alot of anything today, to hot and sunny not to enjoy it. Did take an hr. out to hang the oil tank. Decided to hang the tank over gravel instead of the high point over the patio in case I spring a leak. Still 9' of head which should be plenty at the burner.

Cheers All
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: DavidA on July 11, 2016, 06:41:02 AM
It certainly looks the part.

Edit out the suspension rope it it would make a passable ufo.

Good to see you are making steady progress.

Over here the weather is dull and overcast. Hard to imagine it is well into summer.

Ah well, back into the shed and light the stove.

Dave.
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 11, 2016, 08:48:30 AM
Ha Ha UFO yes. Thanks Dave. Drop the temp. 40* and it sounds like my winters. The dog days of summer are here thier forcasting a week 30+* hot and humid.
Guess I'll spend the day getting some color riding the lawn tractor all day. :whip:

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 13, 2016, 01:55:27 AM
Hello all;

Got a couple of things done today. For safety I changed the direction the hoses connect to the burner, directing them away from the furnace I also shortend the burner blower barrel by 1". Made a base to bolt the fan to, it is held down by 2 large 1/2" wingnuts and is adjustable in or out 2" or easily removed altogether.
It looks putzy but I taped up transition piece to seal joints.One of first castings should be a proper transition piece.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 13, 2016, 04:18:44 PM
Thats it I'm done for today hit 40*C with the humidity out there today. Couple pictures, completed the fan wiring. And moving on did a dry lay-up of the propane fuel trane. Still need to get 2-6" brass nipples and 2 brass elbows to replace the iron you see in the picture. The 2 black quik connects, connect to the 2-30# tanks and the yellow capped POL connects to the 100# tank. The yellow 3 way valve selects either the 100# tank OR the 2 30# tanks. The pressure reducers are rated 0-30 psi and 0-60 psi. The reason for 2 reducers, the dual fuel oil burner will never require more than 15# but the atmospheric burner I plan to build will require as much as 30# or more. Either or both can be used if press allows, no problem on a day like today.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 15, 2016, 08:53:11 PM
Cooled down enough to break out the welder today. Cut and welded up a stand for the propane piping and painted it up. Should be dry enough to install and complete the piping tomorrow. Aquired and installed a barrel pump on my WMO barrel. Hopefully this is the only barrel I will ever need.

Cheers
CB
 
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 16, 2016, 05:36:37 PM
Installed propane piping stand and piped up the fuel trane. Nobody is stocking 6" brass nipples, went with galvanized, could not find a conflict in propane code book. Sprayed all joints down with soap and water and turned on the propane, one small leak at 3 way valve, 1/2 turn on fitting and all is good. Set low press. regulator to 10 psi and high press. regulator to 25 psi for now. Ready for service, will modify a barbecue cover to keep the weather off when not in use. Fittings for my atmospheric burner should arrive Tuesday, refractory and paint and were ready to put a fire in it.

Cheers Modders
CB
 
Title: Re: Dual Fuel Gingery Type Furnace
Post by: DavidA on July 17, 2016, 05:43:52 AM
I take it you will have a celebratory beer cooling in the fridge ready for the occasion ?

Dave. :thumbup:
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 17, 2016, 02:04:35 PM
Ay matee, I got a birthday coming up too, so I think a bottle of the old captains private stock is in order.

Cheers Dave
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 17, 2016, 05:00:25 PM
Almost forgot I still had another crucible failure catch tray to make and install. I used the dome out of what was left of the water tank I used for the furnace shell. Sliced of 2 sides and welded on angle iron sides/slides. Welded 2 more slides under deck. The dome is 3 1/2" deep at center, 1 1/2"s of sand built up on sides will easily contain the contents of a A8 crucible. Now its ready for refractory and paint, till I remember something else.  :Doh:

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 18, 2016, 10:02:15 PM
Spent the afternoon cutting/shaping insulating firebrick. Did a dry lay-up of all the firebrick I will be using . Its not perfect but its a forgiving process everything will be thinly buttered with morter and all interior surfaces covered with a 1" Uni-Cast 70 hotface including the bottom drain hole.The floor will get a 1 1/2" hotface.The burner port is not yet cut in the pictures.I ended up using less than half of the brick I had, so a few projects left thier yet. I also got more than half a 5 gallon pail of fines and offcuts which when easily crushed into granular and mixed with fireclay will make a good high temp insulating castable for the lid.The tops of the bricks will be finished off with 1/2" morter for a smooth finish.

Cheers All
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: Manxmodder on July 19, 2016, 01:58:46 AM
 :clap: Nicely done,CB  :thumbup:
 
 I like your quote:"If time is money,I need a loan"......yeah,me too :)......OZ.
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 19, 2016, 08:46:29 AM
Thanks OZ

When I was young I couldn't wait till tomorrow. Nowadays I'd like to redo yesterday and squeeze in a little more. To many projects to little time. :wave:

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 19, 2016, 03:57:11 PM
Well fittings for atmospheric burner didn't arrive today as promised so decided to cast up lid.
 
The pictures
1. Welded rack bolts to lid and welded ready rod to bolt heads. Rapped rods with wire to support refractory and installed fender washers on ends for extra support.
2. Turned down piece of firewood with slight taper for vent hole.
3. The insulating mix 1 part fireclay 2 parts crushed insulating firebrick.
4. Wrapped vent plug with saran wrap (hopefully it will release). Filled lid with mix tappered down around vent and left 1" for the hotface.
5. Mixed and poured the hotface and made up 2 plith blocks with my leftover.

Covered all with plastic to allow curing overnight. Will give it a light spray before turning in tonight.

Cheers Modders
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 20, 2016, 01:17:18 PM
Cut the burner port in the brick lining this morning. Turned up a pattern for casting the burner tube. It is made in 2 parts because the pattern cannot be removed in either direction as 1 piece. A centered screw allows the 2 pieces to be seperated. The pattern has a 15* flare where the flaring flame would imping on the refractory.

Well my fittings just arrived so I may get that burner done today.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 21, 2016, 12:45:57 AM
Compleated building the atmospheric burner. It is based on the Ron Reil burners and Rupert Wenig modifications. My gas jet is a salvaged air jet drilled to a #52 drill. My bell reducer is 2 1/2" to insure sufficient air at high settings. This burner does not require a fan so when not burning oil this would be the preffered burner, it does require higher gas pressure. Rather than get too long winded here I am including 2 PDF's from Ron Reil's site. If you like this sort of stuff, please visit Ron's site, thiers lots more there.

Uncovered lid and removed vent pattern. Only scared vent hole a little bit.  :) Will leave to dry till it can be fired.

Cheers
CB
 
Title: Re: Dual Fuel Gingery Type Furnace
Post by: Manxmodder on July 21, 2016, 04:13:43 AM
Very smart,CB  :bow: . What is there not to like about 'this sort of stuff'......OZ
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 21, 2016, 11:02:41 AM
Thanks OZ, she may look good but is she hot, if I can build a flare mabye I'll try it out on the vise tonight. Nothing at all I could play with and read about this stuff 24/7.  :D Not everyone is of this opinion though. :hammer:

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 21, 2016, 11:47:50 PM
She's more than hot , She's hellfire. Cobbled together a flare out of a couple of old fittings, wasn't shure it would work, flares are not needed installed in furnace but for bench testing they are neccesary. Moved my portable vise outside and set up for tonight.

Flame pictures
1. Shortly after start up-carburizing flame
2. cranking it up-oxidizing flame
3. Nuetral flame to slightely carburizing-the flame we want for melting
4. Flare turned cherry red in less than 2 minutes after start-up. Here the leading edge is starting to turn yellow. For fear of melting it off I did not go any higher on my settings. Both the needle valve and the choke were less than half open.
5 and 6 are 2 more veiws of the flame.

Hot baby hot. :ddb:

Cheers Modders
CB

Title: Re: Dual Fuel Gingery Type Furnace
Post by: tom osselton on July 22, 2016, 01:38:08 PM
Nice flame!
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 22, 2016, 05:28:09 PM
Hi Tom. I was surprised given how rough the flare was. I cut a 15* taper in the fitting but given the thickness of the fitting it only extends 3/4" into the mouth of the flare, it then flattens out till it makes the jump to the smaller burner pipe size. A proper flare would be a little longer with a full 15* taper. The burner was a little unstable at the bottom end (normal for this type of burner) but settled down as soon as I started increasing the firing rate and remained very stable as far as I took it with a nice steady evan roar.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 24, 2016, 06:29:37 PM
Completed the patterns to finish the refractory pour. Did the big pour yesterday, the bricks have to be soaked in water before installation so they don't dry out the hotface to quickly and the uni-cast 70 has a short work time. This made for a pretty intense proccess and I forgot to take pictures. Left overnight to cure. Removed form and patterns this morning still a little soft so some of the corners chipped. To wait till it hardened up much more would make it very hard to remove form and patterns and possibly cause even more damage. Vesuveius morter is great to repair these touchups. The darker shiny spots is where I have just applied it.

I will let this all dry for another 3 days then I will periodicaly fire it for a couple of days till I reach red heat.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: tom osselton on July 25, 2016, 04:00:43 PM
Nice looking casting well done! :beer:
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 25, 2016, 06:15:35 PM
Thanks for the support Tom. It was a workout for this old body to coordinate, the floor is a little rough it was out of reach under the bottom pattern on the form when I vibrated the works. The plith sits true so its not a big deal. I had intended to apply a high temp. gasket between the bottom two sections, I was convinced it was not needed. If I find this a problem I can still add one on the underside of the middle section.

I guess its ready for a good clean-up and paint job before I light a fire in it.

Cheers Tom :beer:
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 27, 2016, 11:51:33 AM
Did the furnace clean-up yesterday, came across a problem in the lift assembly. The unsuported end of the top pulley was deflecting with the added weight of the refractory, occasionally dragging the cable instead of turning. Not good. I suspected it was to easy a solution when I pulled it out of the junk box but hindsight is 20/20 as they say. So back to the junk box we go. This is what I came up with. Installed this morning and tried it out. Works great no hang-ups.

Cheers CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 28, 2016, 12:44:21 PM
Started firing the furnace to dry out the lining this morning. Tried out the dual burner on gas for the first time. Lights easy and runs good at low end, did not crank it up as the lining started to steam shortly after lighting. The fan inlet damper is barely open in the badly focused flame picture. Shut the burner down when the steaming started to peek. I checked the internal wall temp after shutdown 329*F. I will let cool and fire it a couple more times today going a little higher on the temp. each time.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: tom osselton on July 28, 2016, 01:53:47 PM
Thats the advantage of fiberwool you dont have to worry about moisture! It's coming along nicely though it wont be long now!
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 28, 2016, 04:51:59 PM
I agree Tom fiberwool is nice to work with. Did some work with it at the Kidd Creek zinc smelter. We used to use it to plug refractory cracks in the heat recovery boilers. I plan to use it in a forge I would like to build (to many projects to little time). The brick was free so it reduced my costs considerably and it is of high quality.

Don't know if I mentioned it before but 30 some odd years ago I built Gingery's Lil-Bertha and did some casting. In the first pic. from left is a sander table I cast some obvious beginner problems but it held up longer than the sander. An unused steel crucible still kicking around, some moulding stuff, a set of screw drivers I cast, not recomended for electrical work but indestructable in the shop, plan on casting some more. The black handled srewdriver is like the one I used for a pattern. And on the end a mold rammer still kicking around.

The next 2 pic.'s are a couple conveniences I added to the frame today a peg to hang my burner wrenches and lighting wand and hooks to store propane and oil hose.

The next 3 pic.'s are the second heat today. Got to less than 1/4 on the fan damper before the crucible reached orange heat. Backed off and held for another 5 minutes before shutting down. I don't think having enough air to burn oil is going to be a problem.  :D Sorry about that last pic. trying to focus on the crucible.

Cheers
CB
 
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 29, 2016, 10:21:00 PM
Expected a slow day watching fire in the furnace, not going to happen. Decided to try the atmospheric burner in the morning heat. It lit but insisted on burning well down the pipe. No adjustments I made would get it out of the pipe. Tried it on the vise, good there. Removed Asian welded burner pipe and filed down the weld ridge down the middle of the pipe, tried in furnace, no go :bang:.Because of furnace back pressure the venturi effect of the reducer was not generating enough velocity to overcome the flame advance. My jet was 3/4" from pipe inlet, Rupert Wenig's was 5/8" but some of R. Reil's were as much as the full length of the reducer 1 3/4" :coffee:. I removed the T and jet and went with a straight pipe with a #53 jet drilled in it. After some fiddling to center it down the burner pipe, distance to burner pipe now 1 1/4". Lit on first try and did not retreat into the pipe as I ramped it up. :D

Installed 2 grease fittings on the main lift slides.

The rest of the pictures are my evening heat with the atmospheric burner. Moisture is all gone, developed a few small cracks. If or as they get worse an occasional application of vesuvious should keep it in repair. Included the second last pic. just for the rich color. This was just before I shut it down.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: DMIOM on July 30, 2016, 04:27:43 AM
CB - I can't contribute anything but if there's a new instalment when I log in it its the first thread I open to read the next thrilling instalment.  Thanks for taking us along ....   :beer:

Dave (IOM)
Title: Re: Dual Fuel Gingery Type Furnace
Post by: mattinker on July 30, 2016, 08:51:21 AM
I'd just like to point out that you will almost inevitably have cracking, it's the nature of the beast, a rigid material heated unevenly is probably going to crack, hopefully fine hairline cracks! i wouldn't worry about it!

Regards, Matthew.
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 30, 2016, 09:37:47 AM
Thanks for the kind words Dave. I'm doing what I enjoy and get to share it with like minded people. Can it get any better?  :) cheers :beer:

Yes Matthew have to look close to find few hairlines in hotface. More obvious in fireclay mix in lid. The support installed in the lid should hold things together and the occasional morter application will hopefully prevent any crumbling.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 30, 2016, 08:28:44 PM
Decided to try oil before the paint goes on. Filled oil tank and hung with hose and heater installed, temp. increased from 82* to 104* in about 1 1/2 hrs. Second picture is the burner set-up. Fired up on gas to preheat, when the plith started to glow I cracked open the oil and gave it more air. Over the course of 20 minutes slowly increased oil, reduced gas and increased air. In the third picture the oil is wide open the gas is disconnected and the fan damper is wide open.
The next 3 pictures are with the burner on just oil. Hard to get good pic's the heat exiting the top is tremendous. You can see the oil spray hitting along the wall vapourizing and burning. Burned clean except for a little smoke between the bottom 2 sections. The gasket I talked about earlier and an adjustment of the gun in the burner port should cure this. The last picture is the furnace packed up and ready to move indoors for the night.

Quite happy with the results, with a little more use I should be able to fine tune air-oil ratios and bring it up on oil quicker.

Well thats pretty well it. A couple of coats of paint tomorrow or Monday then build some mold boxes and mix up some molding sand, I can then run some tests on how well it melts metal.

Cheers All  :beer:
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: SwarfnStuff on July 31, 2016, 02:05:01 AM
Most interesting build.
Thanks for the steady flow of updates. Only trouble is that they keep reminding me of my lack of progress with my 15L bucket one.
Still, I have not been idle and the club challenge of building Elmer Vernberg's Horizontal Twin Oscillator #09. I'm nearly done making bits. Then to finesse them into a pretty shine (Hopefully) before November. Oh, there is the little part where it is supposed to run too, but should not be a problem unlike the Stirlings of recent challenges.
We all await the outcome of test melts from your furnace. Congrats on getting it done.  :clap: :clap:
John B
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on July 31, 2016, 09:58:12 AM
Thank you for your interest John, this project has been a bit of a guilty pleasure for me, there is still alot of domestic work to be done around here. Hopefully done this year and I can devote all my time to the real pleasures of building things (anything the list is endless  :)) in my shops.

Cheers John
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 01, 2016, 06:05:33 PM
Guess it's time for the centerfold pictures. Don't see any further changes so I painted the furnace assembly. The frame assembly is Armour Coat gloss rust paint, the furnace shell is Tremclad high heat flat black and the lid is half a spray can of flame resistant paint I had kicking around. If it's actually flame resistant I'll get another can and give it another coat.

Cheers :beer:
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: Manxmodder on August 02, 2016, 05:17:19 AM
Wonderful,CB, just wonderful  :clap: :clap: A really nicely documented method of making a very professional home furnace. Look forward to seeing some melts come out of her.

Coincidently I was watching John 'Doubleboost's' channel last night on casting brass name plates and his use of sodium silicate sand to ensure the detail being preserved in the mold.This led me to a couple of other videos showing how to make your own sodium silicate from sodium hydroxide and silica gel.
All really interesting and useful stuff to know......OZ.

 
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 02, 2016, 10:35:07 AM
Thank you for your enthusiasm OZ, I am looking forward to some melts too. Building some mold boxes today.

I believe I have been to a few sites on sourcing and making your own sodium silicate,  very interesting. Unfortunatelly one of the non-pleasures of living in the sticks is the slow internet service. The few big providers in Canada can't make outragious profits out here  :( but thats a rant for a different thread. Anyway it makes videos too time consuming for me to access.

Cheers OZ
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: tom osselton on August 02, 2016, 02:56:52 PM
Excellent build,  I may use some of the features on my next furnace build, I want one in the garage so I can cast year round with a hood vented outside Im looking forward to seeing some of your castings!
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 02, 2016, 07:57:26 PM
Thanks Tom, yes casting year around in Canada, when I finish insulating and heat my garage I'd like that too.

Made a couple of molding flasks and bottom boards today. Nothing special just 2 light wieght 12" x 13" flasks to get me started.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: tom osselton on August 03, 2016, 03:27:25 PM
I hear you! My garage has had the plywood exposed for 20 some odd years so this year it was taken back to frame and reskinned and that plastic siding attached. I had them build a extra gable on the roof so I can put up some video cameras.
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 03, 2016, 07:19:47 PM
Hello Tom, Yes when I built my garage/workshop I completed the shell and exterior I purchased OSB board and insulation to complete the interior. The OSB board got used on an extention to store firewood and materials and the insulation is still waiting to be installed. Oh well maybe next summer.

Well you can't make molds without a molding bench, Ha Ha well you can but its a pain. Not alot of finess here its made from constuction grade lumber but its very heavy and very sturdy. The bin will hold over 200 lbs of molding sand and the shelf can store 7, 5 gallon pails for another 300+ lbs. The roll bars slide out for access to the whole bin. 2 coats of Tremclad enamel and its ready for use.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: tom osselton on August 03, 2016, 11:17:28 PM
I'm planning on osb for the interior as well.
Your going all out do you mix the sand by hand or is their a muller in the works? I like the bench one that Tubalcain has on his molding bench or Ironmans its bigger but done in one shot!
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 04, 2016, 12:44:00 AM
I will be mixing my sand by hand for now, if I find I am casting enough for it to be a chore then a muller would be in the works. I have 3 or 4 plans  somewhere in my files, I haven't decided Yet. I have a lot of Tubalcain's stuff so I may have that somewhere, Ironman likes his videos so I haven't seen much of his work. The polititions have all promised affordible high speed internet to rural areas but I'm still waiting :(.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: tom osselton on August 04, 2016, 04:12:29 PM
Probably would have a better chance asking Mark to borrow the Facebook drone for testing purposes!
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 04, 2016, 07:50:22 PM
Yes I know Tom but I keep hoping.

Crazy hot and humid today, it was all I could do to paint yesterday's work. Amazing what a couple coats of paint can do to less than great lumber.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: SwarfnStuff on August 05, 2016, 01:42:30 AM
Golly CB, that looks too good to bung sand n stuff in.
  Great job and as for using construction lumber, Hey man, it is a work bench after all.
John B
Title: Re: Dual Fuel Gingery Type Furnace
Post by: tom osselton on August 05, 2016, 03:04:53 PM
Looks good all painted! I'm just wondering if the bin should have been made out of a 2x12 after all its better to have too much sand than not enough for those multi casting sesions.
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 05, 2016, 06:51:24 PM
Ha Ha Ha Yes John I am going to feel bad dumping dirty wet sand and clay into it :)

Tom sounds like you intent on doing a load of casting. For occasional casting I think its better to have most of your green sand in sealed 5 gallon containers on the shelf underneath. Saves you retempering 400 lbs of sand if you let it dry out between casting sessions.

Well that heat wave is going to break tonight  :clap:. Spent the day indoors and built a pouring shank for the clay graghite crucible. I modified surplus oversized fireplace tongs I picked up for a song from Princess Auto years ago for this purpose. After alot of bending and filling and bending and welding I came up with this.

Cheers
CB
 
Title: Re: Dual Fuel Gingery Type Furnace
Post by: tom osselton on August 05, 2016, 08:02:04 PM
Thats not a bad idea having the tangs like that!  I just use the basic ring that the crucible sits in for pouring but a couple tangs like that would stop the worry of tipping it to much. I store my sand in a plastic container also and find that after storage for a while it gets that funky/mildew smell although it does clear up after a while.
With redoing the garage this summer I haven't done anything in the garage but I got my tig set up again yesterday I'm building a vacuform machine that will live at Protospace so I'll have to weld some aluminum before insulating and putting the osb on the walls, should be interesting.
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 05, 2016, 08:40:59 PM
The clay graghite crucible will only be used for a very few # of iron or brass melts. The idea of 20 lb of molten iron or brass popping out of my pouring shank is pretty scary  :zap: could result in serious injury or fire I wouldn't take the chance. For a #8 or smaller I think this will do, for a #10 or higher heavier pouring shanks are required, some with spring loaded retaining hooks and various other mechanisms. For aliminum I plan on using only steel crucibles so welding on hooks and eyes makes it handier for pouring.

You need air tight lids. With all air excluded grouth should not occur.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: SwarfnStuff on August 06, 2016, 02:01:17 AM
CC, the only thing that comes to mind regarding your tongs is a question about pouring.
     Is there going to be enough leverage / grip to control the pour? A crucible of molten brass at that distance might just be wanting to tip out faster than you might like. Would a short bar welded on at right angles 1/4 way down one of the shafts give you more tipping control?? From the pics I gather you are right handed so perhaps on the left side?
        Bear in mind that I have yet to build my furnace let alone do any melting so may be looking for problems that are not there.
       Great re-purposing of the fireside tongs though and the lugs are a great idea. That crucible ain't going anywhere you don't allow.
John B
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 06, 2016, 08:28:01 AM
Hello John, yes this was a consideration when I fitted the 2 bushings on the ends to prevent loss of the locking link. With one hand on the bushings and one on the locking link there seems to be enough grip to prevent unwanted rotation. If I find this insufficient I plan on welding short pipe sections to the ends of the bushings to form a T handle.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: Manxmodder on August 06, 2016, 09:28:06 AM
Following along with great interest,still enjoying every post on this thread  :thumbup:

....OZ
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 06, 2016, 06:17:07 PM
Thanks OZ, I appreciate the support.

Got 250 lbs. of fine sand to mix my green sand with today. Will eventually go with my own local sand but to avoid screening and washing I decided to go with purchased sand to start off with. A few more accessories and were ready to try this out. :clap:

Cheers
CB

Title: Re: Dual Fuel Gingery Type Furnace
Post by: tom osselton on August 06, 2016, 06:35:56 PM
I got sand for mortar from the quarry it is quite fine. The only thing wrong with 250 lbs of sand is having to mix it!  :D
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 06, 2016, 07:11:28 PM
That may be similar to what I have, 85 mesh morter and jointing sand. I have sand pockets on my property that are finer than that but I don't want to get sidetracked with its preperation right now. 250 lbs? na thats a morning stroll before coffee, as long as I don't have to do it every day. :whip:  :)

Cheers Tom
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 07, 2016, 03:42:47 PM
Not doing much this weekend, enjoying the comfortable sunny weather we are getting. I took a couple hr's out this morning to set up my molding area. Decided to set it up in one of the 3 heated shops I have attached to the house. This will allow me to melt on the patio on mild winter days without concerns of frozen molding sand or molds. All sand mixing done on the patio, the only mixing in the shop being the occassional adjustment to temper. With the floor layout complete
now, this shop is ready for a couple of coats of paint to.  :whip:  :)

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 08, 2016, 11:51:14 AM
A couple of things this morning. Took John B's suggestion and added a T handle to the end of the pouring shank. Can't be to safe. I also added a plate across the pouring side of the shank. This will give extra support on the pouring side and I am hoping it will provide a dam to strain the slag and crude from the pour allowing me to dispose of it after the pour. Hope this works slagging a crucible of iron sounds like a pretty dodgy proccess. :(

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 08, 2016, 04:49:44 PM
Put together a pouring and green sand mixing box this afternoon. Its just 2 X 4's with a 2' X 5" 20 guage galvanized sheet metal bottom.I can mix my green sand in it and when I pour it will get a couple of inches of sand in the bottom, set up tight to the furnace I can pour 3 molds comfortably.

Mixed up 150 lbs of molding sand, the formula from one of D. Gingery's books:
150 lbs of sand
10% bentonite clay=15 lbs.
1% wheat flour=1 lbs 8 ounces
1/2 gallon water

Stopped adding water when it still felt to dry and continued to mix a couple times over. Tried the compacted handfull test showed good detail and broke clean without to much crumbling. Moved inside to the molding bench and covered with plastic to finish tempering, Should improve with time as the moisture permeates all of the clay and flour particles.

Cheers
CB

Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 09, 2016, 06:31:31 PM
Had a number of ideas for the pouring shank for my little steel crucible. Commited today and went with this. The wieght balance feels good, hopefully it pours as well.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: Homebrewer on August 09, 2016, 06:39:46 PM
Good looking pouring shank

Sent from my SAMSUNG-SM-G900A using Tapatalk

Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 10, 2016, 10:34:36 AM
Thanks LibbyHillBrewer. If the weather cooperates I'm hoping for a pour tomorrow to try the idea out.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 11, 2016, 05:53:32 PM
They forcast rain for later today but took a chance anyway and decided to run melting tests on the atmospheric burner.
Pictures:

1 The furnace ready to go, 2, 5 lb. charges of aluminum ready to go.
2 2 molds and the ingot mold ready to go, a salvaged SS grinder water pot to be used for the skimmed goo of the top of melt.
3 Safety equipment, pouring shank and Omega temp. meter.

Lit the furnace at 1:32 , gas press. at 20 psi and furnace cold.
1:38 initial charge melted, continued to add metal till pot 1/2" from lip.
1:48 Pot full, checked temp 1382*F , shut furnace down and skimmed melt, inserted shank and poured first mould remainder in ingot mold.
Melt time 16 min. from cold.

Returned crucible to furnace recharged with aluminum.
2:03 burner back on furnace hot added aliminum to fill pot to 1/2" of lip again.
2:16 Pot full, checked temp. 1406*F, shut down burner skimmed and poured.
Melt time from hot 13 min.

For 5 lbs the melt times are amazing. You bairly have time to catch your breath before moving to the next step.
The pouring shank worked like a champ, slide it in and that crucible is part of your arm, very good control.

Cheers
CB

Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 11, 2016, 06:28:46 PM
Continuing on with todays melt. Didn't want to get bogged down making patterns at this point so a decided to cast some more screwdivers and handles and just for a little fun a saucer. As most probably know casting a sauser, cup, and spoon is a classic test the old time apprentice used to work towards to become a molder. He could probably do a better job with just the saucer on his first day than I did here but hey the last time I made a casting was 31 years ago. Of course the difficult part is the cup and spoon. the complete casting requiers a 3 part mold. Maybe someday I'll get good enough to try it. This furnace can certainly melt the metal to keep trying.

So out of this melt I got 2-1.5 lb. clean ingots, 12 stubby screwdrivers and handles for files and punches, and the first step in a saucer cup and spoon casting.  :)

That rain finally did come, more tomorrow so maybe Saterday we will test the dual burner.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: PK on August 11, 2016, 06:49:53 PM
Wow, those melt times are VERY fast!
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 11, 2016, 07:06:24 PM
Yes they are PK I was amazed I had to work just to keep up. They weren't kidding when they called it a "Monster Burner" mine is a little more "monster" because of the larger intake bell. :clap:

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: tom osselton on August 11, 2016, 07:17:45 PM
Nice castings! I have only used the cope and drag never the 3 part system yet one day perhaps I'll have to give it a go.
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 11, 2016, 07:46:29 PM
Thanks Tom. I am not happy with the finish but thats what learning is all about, The finish is a little rough and there were a few small incluesions, maybe my sand needs an adjustment or I am pouring to hot (certainly had no trouble filling the mold) or both.

Yes its an interesting skill testing problem if you go to FOUNDRY 101.COM you can see a picture montage of the whole proccess, very interesting.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 11, 2016, 10:42:36 PM
And here are the 4 stubbies I cast, the flash filed off and wire wheeled to shine them up. Turned out very nice good wieght and will last for my forever. I think at least a dozen more are in order.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: DMIOM on August 12, 2016, 03:25:18 AM
Magnificent CB - so enthralling, forgot to reach for the popcorn!  :clap:  :clap:  :clap:

Dave (IOM)
Title: Re: Dual Fuel Gingery Type Furnace
Post by: SwarfnStuff on August 12, 2016, 03:39:14 AM
Great result CB, well worth the journey and to see the end result Yea.  :beer: :bow: :clap:
John B
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 12, 2016, 09:42:04 AM
Thanks guys. I have enjoyed it to, heavan came early this summer. I am looking forward to enjoying many casting projects over the next few years.

Cheers All  :beer: :beer:
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 12, 2016, 04:50:16 PM
Heres half the contents of the second mold. File handles cleaned up with a file and wire wheel, a few rough spots and a few small incluesions but very servicable. I have a whole drawer full of files so I will be making lots more of these.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 12, 2016, 10:13:01 PM
Just to finish up with the proceeds of this test melt. I was going to put small punches on these stubby handles but decided small files would be a better match.
Feel good in hand, should improve what is often tedious work. Not a bad little haul for a first pour.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: mattinker on August 12, 2016, 11:02:27 PM
Nice to see you've gone from theory to practice!!

Al those nice handles! It would be good if you could varnish or dip them in something, keep the Al out of your system. I'm being treated for heavy metals at the moment, it would be good if you avoided them!

All the best, Matthew
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 12, 2016, 11:45:07 PM
Yes I should vanish them but only to keep them from oxidizing and losing their shine, I'm not concerned about absorbing aluminum from handling them. I would be more concerned if I was raising it's temp. to the boiling point and breathing the gas as would also be the case with zinc or lead only much more toxic and much lower boiling points. There are kitchens with only aluminum pots and pans by that logic alot of people should have been poisoned by now from stirring food at elevated temperatures in aluminum cooking utensils. My understanding is that heavy metal poisoning mostly occers from breathing the fumes or absorbing the liguid such as mercury. Some metals are not toxic your body requires a small amount iron for example any exccess is simply passed from the body.

I feel for your condition but I don't feel you aquired your condition from handling aluminum utensils.

Cheers
CB   
Title: Re: Dual Fuel Gingery Type Furnace
Post by: mattinker on August 13, 2016, 12:38:06 AM
I did not acquire my condition from handling Al, but like other metals, lead
 for example, we absorb through the skin. It has been argued that the oxidisation on kitchen utensils prevents or at least diminishes the picking up of Al in food. I do not intend to argue with you about heavy metal poisoning, my intention is to point out that when we can protect ourselves, it can be a good idea. Alzhymers disease is thought to be associated with Al poisoning.

Al the best, Matthew
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 13, 2016, 01:01:30 AM
No I am not the arguing type either but puting AL in the same ballpark as lead or evan zinc is just wrong. When I worked in the Kidd Creek zinc smelter the lead burners repairing the acid plant worked with supplied air and the area roped of till they were done, now thats toxic yet I could handle lead bars without to much danger its the fumes your body absorbs and condences. Zinc well thats galvanized coatings we all handle them everyday but welders know you don't weld them, most of us shophermits have had a touch of "metal fume fever" from doing so.

The point is we know some metals are toxic and some are not. The jury is still out on AL and in its solid form every one on this earth comes in contact with it on a daily basis. Not to mention that in bauxite form its the second most common element on earth and we are all still here.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: mattinker on August 13, 2016, 02:05:42 AM
The jury is not out on Al, I have high levels of it, amongst other things.

I'm afraid that things are not as clear cut as you imagine!

Regards, Matthew
Title: Re: Dual Fuel Gingery Type Furnace
Post by: RobWilson on August 13, 2016, 03:54:17 AM
Excellent thread CB  :thumbup:

Nice job casting the screwdriver handles ,seeing them  took me right back to when I was a wee lad in school , we made junior hacksaws with  a cast on handle  :dremel: , way back when kids made REAL things on REAL machine .


Rob
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 13, 2016, 07:36:34 AM
Thanks Rob, my playtime doesn't come close to shining a light on the work I have seen you do on these threads  :bow:. I loved shop in school too I have been playing with steel and aluminum in one form or another ever since so this rebirth of interest may be just altzhiemers setting in  :(.

Matthew my imagination is my greatest asset, are you knocking that too now? :)

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: mattinker on August 13, 2016, 08:30:51 AM
GB, I'm not knocking anything, I fail to see where you've got that idea from.

Forget that I made a suggestion, I only meant you well!!

All the best, Matthew
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 13, 2016, 08:42:05 AM
Matthew I got that idea from your initial post I"ll not bore you by quoting it. Your well wishes are kindly noted.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 13, 2016, 04:53:07 PM
Not much to update today,Its been sprinkling for part of the day and threatening worse. I did manage to temper my clay graphite crucible which I had forgoten about. Heated the furnace to 300*F then shut it down and let it sit closed up for 2 hrs. Fired it up again and slowly fired it up till the crucible was a bright red heat, shut it down and closed it up. Will let it sit overnight to cool down.

I also got the used green sand remixed and back into my mold bench. Made an adjustment of 2% clay and mixed it dryer. I am hoping for a little more green strength to reduce incluesions and I think I need to vent more and pour faster to reduce gas in the mold.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: Pete W. on August 14, 2016, 04:41:09 AM
I did not acquire my condition from handling Al, but like other metals, lead
 for example, we absorb through the skin. It has been argued that the oxidisation on kitchen utensils prevents or at least diminishes the picking up of Al in food. I do not intend to argue with you about heavy metal poisoning, my intention is to point out that when we can protect ourselves, it can be a good idea. Alzhymers disease is thought to be associated with Al poisoning.

Al the best, Matthew

My understanding is that high levels of aluminium have been (are) found in the brain tissues of Alzheimer sufferers.  In our household I discourage the cooking of fruits that have strong acid juices in aluminium utensils - I prefer to use stainless steel utensils (but maybe they have problems too? I just haven't encountered that literature.)  It's a policy that has a very low implementation cost!
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 14, 2016, 09:03:37 AM
I don't think a discussion on the health hazards of handling different metal in our lives belongs here. Please start your own thread on this subject if you want to continue this discussion.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 14, 2016, 05:37:02 PM
Well I just melted 12 lbs of iron using the gunk I drain out of the bottom of my vehicle.ha ha ha :) and none to soon.

The pictures:
1. For a first attempt with iron just an open mold of a 11 lb paper wieght. Actualy if it machines well it will make a nice little surface plate for small work.
2. The aluminum part of the pour, all beded in, ready for the cope.
3. The melting set up.
4 Safety equipment, draw your attention to the insulated leather pouring guantlet gloves for the iron.
5 Aliminum pour.
6 Procceeds of aluminum pour.
7 The iron pour.
8 & 9 Yes I poured it ha ha  :) scratched my initials in the pattern :lol:

This burner performed as well as the atmospheric burner, a little slow on the oil but I think the needle valve for thick oil is a bottleneck. I will replace this valve with a gate valve since I still had half my fan capacity available with the needle valve wide open.Total oil use a little over a gallon. Here are the melt times.

1:23 furnace cold, burner on with initial aluminum charge in steel pot, gas press. 10 psi.
1:30 initial charge melted
1:37 crucible full 5 lbs. of aluminum, burner off and poured
Melt time from cold 14 minutes :clap:

1:46 Clay graphite crucible with 12lbs iron, 2oz. charcoal and 2oz lime in furnace,burner on.
1:50 Started to slowly feed oil.
1:58 gas off, oil wide open, fan damper 1/2 open
2:55 Melt bright white, furnace shut down and mold poured. Did not want to take a chance of loosing my K type thermocouple which only reads accurately to 2400* F so eyeballed it.
Melt time 1 Hr. 9 Min. As noted earlier should be able to speed this up by increasing the amount of oil delivered to the burner.

The furnace exceeds my expectations when I imagined the layout for this project. Cost between 500 and 600 dollers not including all the surplus and salvage I have collected over the years and the propane and piping system which would have been installed weather this furnace was built or not. This price may seem low given how much refractory and steel I purchased but that is because I have enough left for 2 more projects. A version of Steve Chastain's tilt furnace for pouring BIG aluminum castings keeps comming to mind (to many projects to little time :lol:).

I'll do one more post on the procceeds of this melt and this thread is done. Happy casting all :D :)

Cheers all :beer: what the heck make that a bottle of the old captains pivate stock  :beer: :beer:
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: tom osselton on August 14, 2016, 08:22:19 PM
Your moving right along how was the sand for the iron? I see others using coal dust in their mix I'm guessing for the carbon.
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 14, 2016, 08:52:21 PM
Moving right along? You must have missed a couple of posts Tom  :lol: I'm done but 1 post. I didn't mix sand for iron since I am not casting iron much It buned the organic flour which is a good think but held up very well. The coal dust is used so when the molten metal hits it, it gases off preventing sand from sticking, which is what the flour did. The carbon is controlled in the crucible which is why I added a handful of hardwood charcoal dust. If you have ever hit a hard spot when working iron you will know why that important.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 14, 2016, 10:24:50 PM
Here's the contents of todays pour. I cut a slice off the lip of the open face iron block. cut very easily without any hard spots to destroy my bandsaw blade, Should make a great little 5 X 5 surface plate for small work.

Rob I have 8 shiny new screw drivers to take you back to your childhood, don't be a stranger say hi, I try not to leave to often. The adjustment on the green sand helped, noticeably better finish on these handles.

And thats all she wrote. :ddb:

Cheer Up :)
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 27, 2016, 05:13:37 PM
Well caught up on some of the work I neglected around here. Took a day off today to play on the computer, made up a 3 part PDF for thoughs interested in building a similar furnace or improving on this design. Considered measured drawings but my use of salvage and surplus materials would make it hard for the home builder to source, use what you have :thumbup:.I included most of the complimentary  :)and constructive :thumbup: comments made here.  Files are zipped to reduce size, heres Part 1.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 27, 2016, 05:54:41 PM
And heres Part 2
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 27, 2016, 06:42:12 PM
And finally Part 3. Darn my slow connection  :bang:. Fall work is coming up firewood etc.  :whip: If I can manage a few days in there for a few worthwhile castings I'll update them here.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: Will_D on August 28, 2016, 04:23:12 AM
Many many thanks CB.

You have put a lot of effort into this project - not only building it but importantly documenting it for the rest of us. I have downloaded the pdfs and something along these lines is on my must do list.

Once again thanks

Will, Malahide, Ireland
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 28, 2016, 12:16:20 PM
Thank you for the positive feedback Will_D.
Good luck with your build  :thumbup:.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: RobWilson on August 30, 2016, 03:07:35 PM
I am liking the new shinny batch of screwdrivers CB  :dremel:

Now why did I not think of doing that  :scratch: 

Always good to see some foundry work  :thumbup:

Rob
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 30, 2016, 03:27:35 PM
Glad you like them Rob, like I said not recommended for electrical work but indistructable  around the shop.Did not coat them, loosing their shine but even oxidized they look good. 2 of the blades were a little of center but the finish was great. :)

Been raining on and off for the last 4 days so I am stuck inside. I got outside work to keep me busy for a while but I am going to try and get in a few casting sessions before the snow flies. :clap:

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: RobWilson on August 30, 2016, 03:50:38 PM
Me being ignorant  :palm: and curious CB  , when does Canada get its first snow falls ? and how deep does it get in your neck of the woods ? 


1mm is deep where I live and brings the country to a stop  :bang:

Rob
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 30, 2016, 04:13:41 PM
Not ignorant at all Rob you have to experiance it to know it  :) I have had very few Halloween's without wet snow flying, but October is a funny month you could get hit any time. As far as accumulation the last 2 decades have been all over the place one wild year we had green grass in February :clap: other years we can get as much as 5 or 6 feet. :(

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: RobWilson on August 30, 2016, 04:25:44 PM
Cheers CB  :thumbup: 

The UK would be seriously f*&ked if it received 5 foot of snow   :Doh: . anyway enough off topic  .

Will you be getting around to building a casting shop , for all year round melting of metal ?



Cheers Rob
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 30, 2016, 04:49:12 PM
Rob you have been eavesdropping on my brain. The 12 x 16 room pictured below was divided from the back of the garage/workshop for that purpose but its taken so long to get here that its turned into storage. When I get the garage/workshop insulated and heated that is still the plan for this room.

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: SwarfnStuff on August 31, 2016, 02:31:30 AM
Ha, Just shows the accuracy of the maxim that any vacant space will attract stuff, stuff and more stuff. Same thing for horizontal surfaces in the workshop. All mine are loaded to overflowing. Another clean up day is in the offing and then, ... I will need something I just tossed.  :bang: :bang:
John B
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 31, 2016, 03:44:06 AM
I hear you John, I did a thinning out of my accumulating junk boxes a few years back, and sure enough some time later in the middle of a project I needed something I distinctly remembered throwing out thinking I would never need it. :doh:

Cheers
CB 
Title: Re: Dual Fuel Gingery Type Furnace
Post by: tom osselton on August 31, 2016, 05:24:15 PM
Not ignorant at all Rob you have to experiance it to know it  :) I have had very few Halloween's without wet snow flying, but October is a funny month you could get hit any time. As far as accumulation the last 2 decades have been all over the place one wild year we had green grass in February :clap: other years we can get as much as 5 or 6 feet. :(

Cheers
CB
Same here around the end of October but it rarely gets more than 2" - 4" deep unless there is a drift, last year I think I shoveled snow maybe 5 / 6 times then the Chinook winds come and melt a lot of it.
When we were kids living in Victoria Bc we got sleds for Christmas but had to wait  3 years to use them!
Your just too far east!
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on August 31, 2016, 10:52:24 PM
No Tom I'm right where I want to be. Between the ice storms, floods, fires and tornadoes that have been making the news in your area the last few years I would be a little uneasy . Winter has its charms as do the changing of the seasons, my only bitch is the added chore of snowblowing my laneway which takes away from my shop time. :(

Cheers
CB
Title: Re: Dual Fuel Gingery Type Furnace
Post by: Manxmodder on September 01, 2016, 09:56:27 AM
I don't think a discussion on the health hazards of handling different metal in our lives belongs here. Please start your own thread on this subject if you want to continue this discussion.

Cheers
CB

Absolutely right,but worth mentioning that it would be ill advised for anyone to consider drinking the molten contents of a crucible as it may prove injurious to ones health  :)

Keep up the fascinating posts......OZ.
Title: Re: Dual Fuel Gingery Type Furnace
Post by: inthesticks on September 01, 2016, 10:23:56 AM
That sounds right OZ I have no argument there. I would have mentioned it but I figured the site disclaimer covered it. :D :)

Cheers
CB