Author Topic: A bit of casting (Read 31907 times)

Rob.Wilson · « **on:** November 14, 2010, 11:33:17 AM »

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 · « **Reply #1 on:** November 14, 2010, 11:46:05 AM »

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 · « **Reply #2 on:** November 14, 2010, 11:56:04 AM »

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 · « **Reply #3 on:** November 14, 2010, 12:28:45 PM »

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 · « **Reply #4 on:** November 14, 2010, 01:08:34 PM »

Really classy work.

Better luck next cast, Rob!

David D

Bluechip · « **Reply #5 on:** November 14, 2010, 01:21:48 PM »

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 · « **Reply #6 on:** November 14, 2010, 01:28:42 PM »

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 · « **Reply #7 on:** November 14, 2010, 01:43:59 PM »

Quote from: Rob.Wilson on November 14, 2010, 01:28:42 PM

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 · « **Reply #8 on:** November 14, 2010, 01:44:31 PM »

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 · « **Reply #9 on:** November 14, 2010, 03:02:18 PM »

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 · « **Reply #10 on:** November 14, 2010, 03:14:22 PM »

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 · « **Reply #11 on:** November 14, 2010, 03:21:33 PM »

Looking good Rob

Stilldrillin · « **Reply #12 on:** November 14, 2010, 03:47:41 PM »

Oh BUGGA!

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

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

David D

Rob.Wilson · « **Reply #13 on:** November 14, 2010, 03:59:51 PM »

Hi David

BUGGA was not the word i used

At least your flywheels will be easy

Rob

Powder Keg · « **Reply #14 on:** November 14, 2010, 04:14:15 PM »

So whats it made of? Mold wash?

Rob.Wilson · « **Reply #15 on:** November 14, 2010, 04:30:58 PM »

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 · « **Reply #16 on:** November 14, 2010, 04:35:19 PM »

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 · « **Reply #17 on:** November 14, 2010, 04:45:15 PM »

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 · « **Reply #18 on:** November 14, 2010, 11:53:05 PM »

his sound about right?

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

Dean W · « **Reply #19 on:** November 15, 2010, 01:42:43 AM »

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 · « **Reply #20 on:** November 15, 2010, 02:37:35 AM »

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 · « **Reply #21 on:** November 15, 2010, 03:06:24 PM »

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 · « **Reply #22 on:** November 15, 2010, 04:30:34 PM »

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 · « **Reply #23 on:** November 15, 2010, 06:38:30 PM »

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 · « **Reply #24 on:** November 19, 2010, 02:03:35 PM »

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

arnoldb · « **Reply #25 on:** November 19, 2010, 02:31:00 PM »

Looks like you have the weekend all booked up Rob - nice patterns

- It's about time you got the wood lathe sorted

- I'll be looking at satellite pictures of the north of England this weekend - the spot near Newcastle where there's no white stuff should be where you are then; all snow melted away from running the furnace

Kind regards, Arnold

NickG · « **Reply #26 on:** November 19, 2010, 03:03:18 PM »

Truly amazing stuff Rob - by the way, I'm not too far down the road, near Darlington but work up in Birtley - not quite a Geordie but not far off!

I've only ever cast a very simple component in aluminium before my dad retired as a teacher. I made the pattern for it and realise how labour intensive those must be! Sorry if this is a stupid question, but how do you get the core to stay in the right place? or do I just need a

Great work, thanks for sharing it all.

Nick

Stilldrillin · « **Reply #27 on:** November 19, 2010, 04:05:31 PM »

Beautiful work, as usual Rob!

Good luck!

David D

Rob.Wilson · « **Reply #28 on:** November 19, 2010, 04:29:22 PM »

Cheers Lads

Here you go Nick ,good question ,,, The pattern has core prints on it ,, the part painted black (good stones tune

) ,, this leaves a print in the sand for the core to rest on .

There are other methods of positioning the core ,, that i will show on a later job

If your interested your more than welcome to call over on Sunday ,,, i will demonstrate it to you on a Rider Ericsson cylinder

, no tax or import duty

Rob

Brass_Machine · « **Reply #29 on:** November 19, 2010, 09:08:28 PM »

That answers a question that has been bugging me for awhile!

I see now. Very cool.

Eric

Powder Keg · « **Reply #30 on:** November 19, 2010, 09:15:52 PM »

I can't wait to see the patterns and core for Robs cylinder should be pretty neat!!! That gives me an idea for a door for my atlas shaper. Thanks

sbwhart · « **Reply #31 on:** November 20, 2010, 01:29:24 AM »

Fantastic stuff Rob,

That door is amazing can't work out how you did the louvers, did you use some sort of filler ?

Stew

Rob.Wilson · « **Reply #32 on:** November 20, 2010, 04:16:30 AM »

Thanks lads

Maybe i should start a step by step pattern making to casting thread

Hi Stew like this

Cut this shape

Then cut diagonally along its length

When tipped over its a louvre

Good thing about the shape of a louver its a self drafting shape inside and out

Rob

Trion · « **Reply #33 on:** November 20, 2010, 06:52:56 AM »

Just beautiful work Rob!! I'm really looking forward to seeing the machine cover after it's cast! The pattern looks like a stock unit!

NickG · « **Reply #34 on:** November 20, 2010, 09:41:26 AM »

Ahh, clever stuff, thanks for explaining.

Am having a rare trip to the pub tonight with the wife whilst mum looks after my two sons for a while, so I'll probably not be feeling my best tomorrow

, Would love to come and visit at some point though.

Nick

Powder Keg · « **Reply #35 on:** November 20, 2010, 09:45:01 AM »

A pattern making thread would be super Rob

Rob.Wilson · « **Reply #36 on:** November 20, 2010, 04:26:36 PM »

Cheers Lads

I will have ago Wes

Not allot done today ,, had to wait for the new washing machine to be delivered before i could fire up the furnace ,, was supposed to arrive 9 to 10 am ,, what time did it arrive ,,,,,2 .30 pm

Any way i did get a bit casting done .

Here are a couple of shots of the Door ,,,,,, i had cast this a wile back ,,, i just have the frame to cast

Rob

Stilldrillin · « **Reply #37 on:** November 20, 2010, 04:58:12 PM »

Cor!

Those all look rather nice!

Bronze flywheels, I guess?

David D

Dean W · « **Reply #38 on:** November 20, 2010, 06:18:33 PM »

I'll tell ya Rob, I'm never let down when I have a look at your threads! Your pattern making is so nice,
I'd be tempted to use those for the parts themselves. These most recent castings are simply beautiful.
Thanks again for showing us how it's done!

CallMeAl · « **Reply #39 on:** November 20, 2010, 10:46:11 PM »

Stunningly well done! I sure enjoy seeing your work and learn something every time you do a thread on your casting process. Thanks.

johnbaz · « **Reply #40 on:** November 22, 2010, 04:21:30 PM »

Wow!!!

Fantastic jobs there Rob!!, did you get the moulds good and hot before you poured the metal??

Years ago at work when our foreman went home at 5pm, we stayed while 10pm and used to make bits and bats (nothing as nice as yours though!!)

We made cannons, ash trays ornaments etc but weren't set up for small brass jobs as it's a heavy iron and steel foundry where i work..
I made a few parts for guns and swords/knives but that's about it, my mate made a cup, saucer and teaspoon all in one using drawbacks, it would have been perfect except for a very small shutt in the spoon (the thinnest section)..

Here are a few of the cannons we made..

Good luck with the next pour for the water jacket

Cheers, John

Blade · « **Reply #41 on:** November 22, 2010, 04:22:06 PM »

That door casting is amazing! Great job!

Rob.Wilson · « **Reply #42 on:** February 27, 2011, 03:31:55 PM »

Hi Lads

Spent the weekend in the shop casting

and finally got to grips with Bog's water jacket

Here are a few that did not make the grade ,, all have defects ,,,,,,,,,,,, i think i went through every type of casting defect getting this to cast correctly

I will photograph and list the faults and causes with these before they go back in the pot

One i cut up to check the wall thickness

All in all a fun/interesting casting project ,,,, i am a tad wiser for it too

Cheers Rob

Dean W · « **Reply #43 on:** February 27, 2011, 03:43:15 PM »

That piece for John looks great, Rob. I've machined quite a number of cast parts. The one you have there
looks as good as any I've seen, from any company. Great job.

Dean

Stilldrillin · « **Reply #44 on:** February 27, 2011, 03:56:52 PM »

Beautifully done Rob!

Persistence paid off, in the end.....

David D

Powder Keg · « **Reply #45 on:** February 27, 2011, 04:02:16 PM »

Those look really great Rob!!!

doubleboost · « **Reply #46 on:** February 27, 2011, 04:06:08 PM »

After looking at these castings today and realising the amount of work Rob has put in to them .

I dont envy Bogs having to machine them

saw · « **Reply #47 on:** February 27, 2011, 04:41:32 PM »

You are doing a fantastic job Rob.

sbwhart · « **Reply #48 on:** February 27, 2011, 05:33:30 PM »

Lovely bit of work Rob

Nice even wall thickness

And a nice big B

I now John will be over the moon with it.

Stew

Divided he ad · « **Reply #49 on:** February 27, 2011, 06:31:46 PM »

Rob....

A great deal of effort went in to these obviously

I was at Johns today when he got your PM (Had a natter with Stew too

)

I know he's very happy with the job. We discussed the process and the finished product... Both most impressed at the result

I am still watching tube videos and reading on how you get the inner without using "the force" to hold the core off the outer pattern??? Black magic I tells ya!

Ralph.

Bogstandard · « **Reply #50 on:** February 27, 2011, 09:54:14 PM »

John DB,

I do realise how much work Rob has put into it, he has sweated blood for me on this one.

How he has taken my grotty little sketch to fruition has amazed me at every step, and now seeing the finished article brings a lump to my throat, a true artisan at everything he does. A massive undertaking on his part just so that I can have a totally unique engine, I just hope I can make the rest of it to come up to the standard required.

I don't think people realise just how large it is, it stands over 9" high.

I actually called it off in ali, but being the person he is, Rob insisted it was to be of bronze.

The quality he has made it to means that very little machining will be required, but unfortunately it will be having a coat of paint, as that is what the finished article calls for.

Such a shame to cover up all that artistry. But needs must.

John

NickG · « **Reply #51 on:** February 28, 2011, 07:30:19 AM »

Brilliant! Really need to make the journey up one day Rob to see this excellent stuff first hand.

Rob.Wilson · « **Reply #52 on:** February 28, 2011, 04:34:27 PM »

Thanks for all your comments lads

If your in the area your welcome to call in Nick

,,,,, any excuse to fire the furnace up

Rob

saw · « **Reply #53 on:** February 28, 2011, 04:42:30 PM »

It's a long tripp, but if I am in the naverhood then...

Rob.Wilson · « **Reply #54 on:** February 28, 2011, 05:03:32 PM »

Your welcome to Benni

Rob

Brass_Machine · « **Reply #55 on:** February 28, 2011, 09:01:21 PM »

I got to see these in Rob's hands (via skype)... They are quite large. They came out fantastic though!

Eric

News:

Author Topic: A bit of casting (Read 31907 times)

Rob.Wilson

Rob.Wilson

Rob.Wilson

Rob.Wilson

Rob.Wilson

Rob.Wilson

Rob.Wilson

Rob.Wilson

Rob.Wilson

Rob.Wilson

Rob.Wilson

Rob.Wilson

Rob.Wilson

Rob.Wilson

Rob.Wilson