Casting a Bicycle Bell

[Powder Keg]

I'm thinking of making a bronze bell for my Penny Farthing that will kind of fit the antique theme that I have going. This little project will let me do a couple things that I have wanted to do. Mainly cast a bell. For some reason I have always wanted to do that? This way I will have a use for it. I will get some more experience in pattern making.  And hopefully have a useful device when done.

Doing some research on such things, I found a couple that I like. Here are some pictures I found on a German site.







I plan on making it an ornate bell. Like this pattern with out the letters.



I think I'll start gluing up some wood for a pattern tomorrow.

So, I'm thinking about casting the bell with the ornate side down and poring through a sprew in the center. Kind of like an upside down umbrella. That should work, Right?

Later, Wes

[Powder Keg]

After doing a little research, I noticed that most bells are cast right side up. I'm thinking so that the liquid metal doesn't "wash" away the sand? Thoughts?

[Brass_Machine]

Want to see this done. I don't cast, so I can't help... Maybe Rob can?

Eric

[sbwhart]

Thats an interesting bell set up Wes I take it the tyre bobbles activate the bell when the little wheel is moved into contact.

Thats a nice lap as well will that be next 

Stew

[Rob.Wilson]

Hi Wes


Never cast a bell myself ,,,, so i am interested to see how this works out 

I would go for this way
 

This way has problems


Rob

[Powder Keg]

I hadn't thought of removing the sprue (yet:o) It would have come to me at some point though

I have some Poplar that I'm going to use. I'm thinking of gluing up 2 or 3 layers. I think this way the grains will be going different directions and will help minimize pattern warpage. I really like poplar because the hard and soft grains are about the same.

I'm thinking that I'll make the wall thickness about 3/16" I don't really have anything to go on as far as how thickness will affect the tone of the bell. So It might be a little hit and miss?

Thanks,

[AdeV]

I suspect the thicker the bell, the shorter (& quieter?) the ring. Unless you plan to carry a small hammer with you to hit it with of course! I've seen them tune church bells by shaving off metal around the lip, I imagine your tuning method would be similar.

[rleete]

For something that small, thinner is better.  Thicker will be sort of flat, unless you really whack it.

[Rob.Wilson]

I think they cast bells on the thick side ,,, then machine the inside to get the correct note .

Rob

[Powder Keg]

Well I managed to get a little done today. I cut out some wood circles and glued them togather.



After a while the glue dried and I was able to start turning. I roughed out one side and turned a little stub to hold onto.



I then drilled the pattern a little short of the depth I am aiming for.



I then hogged a little of the wood out of the center.



I stopped here. I need to make a couple templates to machine the wood to. I'm thinking about making it slightly thick. That will pore better. I will then machine some of the thickness out of the inside to tune it. That's my plan anyway. Thanks for the input.

[CallMeAl]

This looks familiar. I did some wood turning on my metal lathe, it works well, but what a mess!  It convinced me to buy a wood lathe for the wood stuff (actually that was my excuse for more tools).  I'll be watching how this turns out since I too have always wanted have a go at casting a bell!

[Stilldrillin]

Love how the original is tyre powered.......   

What a crackin' project! 

Good luck Wes!

David D

[Powder Keg]

Got some shop time today. I need my lathe back, so I finished the bell pattern.  I drew up a template. It worked better than I thought. Here I roughed out the inside and a little/lot sanding later. It fit pretty nice.



Same with the outside. I made a little arbor that the pattern is bolted to with a central bolt. I got the thickness down to a little over 1/8" it seams kind of thick? But I was getting some chatter. We'll see if it rings after I cast a couple.



Also It will have a thinner wall thickness once I get the outside carved.

[doubleboost]

That is a nice piece of wood turning of course you realise the lathe is now contaminated for life

[Powder Keg]

This lathe is so old and wore out that a little sawdust is the least of it's worries I think I about have the pattern I'm going to carve on the bell about figured out in my head? We'll see.

[Powder Keg]

A little more research and I notice that Bell Bronze seems to have more tin in it than others. 20 percent compared to about 10 percent found in most other bronze. I found some pure tin on Ebay and am thinking of getting it to make my own scrap bronze higher tin content alloy Might be fun?

[Powder Keg]

Hey Rob, Are you using enough cow Dung in your foundry operation???

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This is pretty interesting though. I've had lots of trouble with Bronze and these guys are using cow dung and bees wax and charcoal. Makes me wonder what I'm doing wrong

[Powder Keg]

There is a ton of pretty neat stuff pertaining to bells here. Lots of information.

http://www.russianbells.com/interest/biggest.html

Largest ringing bell!!!

[Rob.Wilson]

  I , Wes ,,,,,,,,,,, i can just see the look on the wife's face ,, when i come home with a sack of  cow poo 



Great videos    interesting stuff 

Rob

 

[Dean W]

I hear meadow muffins are where the casting trade is headed, Wes.  You gotta follow the experts!  ; )

[doubleboost]

Interesting videos 
Not a great deal of health and safety

[andyf]

I hear meadow muffins are where the casting trade is headed, Wes.  You gotta follow the experts!  ; )

Or, spade in hand, follow the cattle......

Andy