Casting Aluminium Roundstock From Free Scrap
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- เผยแพร่เมื่อ 12 ก.ย. 2024
- In this video I am showing you how to cast solid high quality aluminium roundstock for free from scrap metal. This method may work with other metals too so you dont have to use only aluminium.
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A metal belt grinder was my first thought. Now you have a welder to make the steel structure. You can cast aluminium round stock with your forge and you can turn the pulleys from the aluminium on your lathe. Such a grinder should be a very nice addition to your shop since you do quite a lot of metal work, and blade making etc. The belts for such a grinder should last longer then the sandpaper on your wood belt sander.
+1 for this one, and when you're done, use it to clean up the parts as in my other suggestion :D
i made a video about my homemade belt grinder i'm 14 years old
I'm a woodworker and have never cast anything out of any type of metal, but this was really fun to watch! Good job!!
To make larger diameter items turnable with your current chuck, you could always make your mold (the steel tube) stepped. 50mm then a step to 200 mm or whatever.
I wonder what kind of person would dislike this kind of video... its not a bad science video, its not a political video, heck its not even an opinion video... its educational... do you think he did something wrong with it?
This question is up with the "what's the meaning of life", "is there intelligent life in space" and "how much air is it in a lays chip bag"..
Adventurer From Sweden 42...
Seriously though, is there any intelligent like here on earth though
+Sean Britton did you mean "life" not like. haha sean I think not.
Every aluminium dealer :D He makes them redundant. ;)
bad people with nothing better to do than troll the interwebs
for the slag when using soda cans which has paint on the outside and a thin plastic on the inside, use household salt.
a tablespoon or two (maybe 3 or more depending on how much aluminum you are melting) will reduce your dross by more than half
Did he mention it was free?
At the beginning yes
lol I think he's joking cause he mentioned it so many times
;-)
Yeahyeah everything is free as long as you have all the things you need..
he sounds like he's being watched
k torgs bahahahahhahahaha!
techinically he is
At least he sounds smart
Dude, I gotta say. You are really knowledgeable and freaking skilled. Love what your doing.
if you have a car, make custom shifter nobs, I'm a machinist and Ive been making cool shifter nobs for me and my friends when it's slow at work! they look pretty nice with flutes down the side too if you have access to a mill with a indexing head!
I can't believe I've never tried this. We have everything necessary in the shop, it just never occurred to me. Great tip.
You'll get a lot smoother finished surface, if you'll grind your high-carbon tool steel cutter bit with a goodly radius, & lots of relief. Since you're cutting aluminum, you need to run at a higher RPM. If you machine threads, your "cutting oil" is Turpentine. thanks for your video. I wrote another comment on reversing your chuck teeth, and I didn't thank you in that video...I had to post it in order to go back thru your video to remind myself what the subject was that what else I was going to comment on. Sorry 'bout that. I did enjoy your video. Keep em coming.
not bad! I really like the clarity you help give in what you can do with scrap materials, and turn it into something 100% usable for making something new with. also kudos on at least making an effort to include the trimmings. maybe just collect them in a bucket, by metal type, and washing them in a soapy water to wash the oils off? I figure doing it in batches like that means you won't have to do that very often. and maybe make a screen in a spare lid to drain the soapy water and rinse water out with. I might do that myself.
If you feel limited by your chuck, cast yourself a face plate. I highly recommend one of the How to run a lathe books by Southbend or Hercus, etc. Any commercially available workholding device can be replicated with shop cast Al, with the exception of a centre for your lathe for turning between centres - incidentally, another great way to turn round work pieces.
u just keep on WOWING me with everything u do. nice job.
Good job! This one is simple yet very useful
Grant Thompson! 💪
You guys really inspire me!
make a small bat. i turned one out of wood for fishing and it turned out great.
google kalapappi if u have no idea what i just said
Why make a bat for fishing?
+glockfan112 a knife is slow and bloody
Always use a knife if you want to keep the fish good... You need to let the blood out of them.
its a club for killing fish right?
A very informative video, have been thinking of doing this with brass for turning on my lathe, Thank you.
Brass is a bit more interesting because of the zinc! It tends to try to boil off during the belt. So, as long as you do it on a breezy day, you'll be fine!
hey bro. i did not watch your videos for long time. and now i recognise your voice from your pronunciation of "aluminium". you have grown up now and more skillfull. congrats. i wish you bigger success.
As far as simple lathe projects go I always enjoyed little steam engines, but you seam like you are more into weapons, making custom arrowheads is always fun. 😀
A project we did at achool was a small replica cannon - turned tapered body with "reinforcement rings", and a cross hole for a support piece, then a wooden carriage with wheels. Also look good (in fact, possibly better) in brass.
The main difference between cast aluminium and commercial stock is the commercial stock is rolled & or extruded which dramatically improves the microstructure.
Just means this material will be relatively brittle.
Carbide tooling works fine on aluminum if you know how to use it. It requires a much higher cutting speed than HSS and a deeper cut. Most people try to do .001-.002 "finishing cuts" which will never work with carbide. It just tears the metal. Crank up the speed to about 1200-1400 RPM and take a .008 cut and see how it works.
Really nice job (as always)... but by "free" you mean "let my parents care about the electric bill". Right? ;) Keep on exploring... I love it!
The chuck, in your video, is actually a reversible chuck. Unplug your lathe! Clean the movables well and the chuck face. Label each A, B, & C. Also, write the letter beside the movable, on the chuck face. Insert your "T" wrench & open the chuck till the movables don't move out anymore. see which one comes loose from the face threads first, second, and third. Remove "A" from its slot & turn it 180 degrees (end for end) & slide it back in its slot. do that for the other two jaws. Now, hold the jaws back, so they won't engage until its their time. The jaw that came loose from the face threads LAST, must engage FIRST, and so on. Just a little inward pressure and a turn of the "T" handle, will re-engage the teeth (jaws). Now your chuck has 3 different sets of BIG, to clamp from. Just be sure to push your stock all the way back against the jaws, & tighten real tight. Also, its a safe idea to center-drill & use a "live Center" in your tailstock, any time you're using a large diameter piece, especially if its an odd shape like cast. if the ends are not square, cut it off square, before inserting it into your chuck, to prevent wobble, and to have as much surface area being gripped, as possible. (( I've been a machinist for over 55 years ))
I almost never like videos, but you deserved this one keep up the good work!
instead of remelting the shavings you should turn them into thermite
I thought thought that only worked with iron?
+Travis Bohanan it's a mixture of iron oxide and aluminium powder.
Silent Warrior they do
Except aluminum
Glen Phenix lol
just wash your turnings with dish detergent in a dime store plastic pasta strainer. if you make really fine chips, use one of those screen hemisphere rice strainers. for borax, just use the local equivalent of "20 mule team" laundry borax. great series, and ideas. love the trapeze mount crucible, lol. i'd say a great idea for a project to test your mettle as a metal caster is a functional section of chain, made in a single pour. you could probably get 10 vids just on the failed attempts, lol.
spinning tops are a good project quick and easy and look really cool if you make a hybrid out of steel and brass
now you can make lightsaber hilts
good idea the shrinking aluminum no need to split the mold you can make a lead hammer for doing all sorts of things if you use oil used motor oil 20 cents a gallon it gives the highest heat you can melt cast iron to make your self a milling mashie you can use your lathe as one until you get the big one built use old truck bearings and keep the parts they rest on as well or put them on your castings your self good luck .
Awesome video bro I've been subbed to you for like 2 years or so and I've watched almost every video you have on you channel!!!! Keep up the good work and good luck on your exam results 😀😀😀😊
amazing work as always
Those look really good! 🤓
wish my friend owned a lathe I could borrow! not all that common in the states. When there's one for sale its rather pricey also.
harbor freight has semi decent lathes for reasonable prices
+Samuel Scott thrre for woodworking I thought
lathe and well equipped workshop. This guy is just lucky having the right father. Without this, he wouldn't be able to make those projects.
A woodworking lathe should actually work fine for aluminium since it's so soft. You'll need to make your own milling mechanisms though.
try craigslist just always be looking you eventually find one cheap or David gingery it out
Great video. You should try making some parts for things or even make your own coins from the aluminum.
Another great video! Please make a guide on how to make a cpu water block of copper!!
that's pretty cool how you can make that I might try it one day keep up the good videos.
Step by step and very informative. Very well done!
make a set of chess pieces! make a narrow pice of stock 1-1.5" and turn pawns and rooks and such. you could then anodize it different colors!
+1 for the anodizing, but chess sets have been done to death... Maybe a Quarto set, instead.
or that. that would be pretty sweet.
Make one side out of copper.
Cast aluminum does not anodize very well. It will be very blotchy.
Great video as usual!
An alternative to reversible jaws could be to make the mold wider with a thin part for gripping at one or both ends.
Try to make a aluminium spinning top with the lathe!
how much did these cost to make ?
Just watched a vid from last yr. Puberty hits hard.
Very good video. I think that you can reverse the jaws on your lathe, it just wont be in a 1 -- 2 - 3 sequence, definitely keep track of which jaw went where. It can be a pain, but it can be done, when you have the sequence done right it will be obvious. Good luck, keep up the good work !
a good fun project for a lathe is making pens. pretty easy and quite fun
u could turn between centers with a home cast lathe dog and faceplate for larger diameters, like they did in ye olden days./ the dogs and faceplate would be good videos too.. You could then machine a tiny cannon out of scrap brass shell casings if your furnace can handle brass.
If you keep turning your T on your chuck the jaws should be able to come out and you can turn them around for larger diameters. Also if you have and inside diameter you can grip the ID of a larger OD bar stock.
Awesome. I will try this.
Fantastic. I am building a replica 1928 Morgan RIP killer MG special 3 wheeler with 4 wheels. I am going to cast my own stock so I can turn it down on my lathe to make adapters for an experimental aircraft engine to an MG 4 speed tranny. Thank you for the information.
Since you have an electric forge with temp controller, you could try casting glass, because it requires you to turn down temperature step by step so it won;t crack.
Some 3 jaw chucks are reversible but you reverse no.1 jaw and put it in no.1 position then reverse no.2 and no 3 and swap there position no.2 in no3 and no3 in no.2 being careful they thread on properly and when there closed they are all even
The back side of his lathe jaws are not cast nor machined for much gripping power, which means they probably wouldn't hold very well in larger diameters.
what if you pore it and let it cool down in a vacuum-camber will that get rid of air bubbles in the cast so it has less blemishes
you could turn a tapping die holder for your tail stock. make some custom handles for the lathe. a small cannon. a kubotan. I teach engineering and I'd be happy to answer any questions you may have even though you're doing very well on your own.
Go to local car boots, they almost always have lathes and jaws for sale. It's the best way to get hold of cheap tools for older models
to save lathe shavings put them in a big zip lock bag with a couple of ounces of dishwashing soap and the rest water, shake them up good then drain water out of bag and refill with clean water and shake again, then put wet chips in flat pan to dry and remelt
i think a cob led flashlight from one of those round stocks would be a killer build/video. The body itself would be the heatsink
you should sand the inside of the tube smooth and get even better results in taking out the bar stock. might reduce how much your have to turn it.
you can turn your jaws around and be able to turn something. a little bigger if you got the swing or just make some soft jaws yourself. remember a good tool maker will always make it if he can rather than buy it you know it's quality and you show your skill
Make larger diameter pieces and then just bore them out about 1" deep and at a diameter to fit over your chuck jaws when totally closed. Then just open the chuck to secure your bigger stock to that you just bored out. Wait that will not work so instead make that shape in your mold at the bottom, but make sure its centered to your pipe. Then you will have a recess that your chuck can open into so as to grab the part. Now you can use the chuck jaws you already have.
Carbide cutters don't really like to cut so much bit they like to plow with heavier cuts to make a nice surface finish. Hss cutters like the light finish passes with a lower surface speed. But generally with aluminum it's soft enough to cut easy with any cutter. If your carbide is not cutting aluminum nicely first check to see if the edge isn't worn off the insert and take a deeper cut.
If you want a perfectly smooth, continuous finish, turn the whole piece between centres, so you can do one cut down the whole length - but I'm sure you knew that! Again, great work, you should be chuffed.
you can always wash the aluminum shavings with dawn dish soap then rinse to get rid of the oil.
You can use an arbour to hold larger diameters
Or turn between centers.
You are a very skilled wood worker... I have a challenge.... Build a pretty large wooden plane... Make it a model or working ur choice, I've built a spitfire that's wing span is 29 inches from wood... Do you accept the challenge it requires a large depending on the plane
I have to admit, it looks like really good quality. When I first saw the title, I immediately expected big pockets of pourosity but that surface looks fine. You may find a little more towards the center of the stock but hey, that's always the problem area. Great job!
Maby you could weld a small and a big metal pipe with a steel plate in between them that has the same diameter as the small pipe together. Maby you are able to create a roundstock with two different diameters. You could clamp the thinner part in the chuck of the lathe. That might make it possibel to make a roundstocks with a bigger diameter and you dont have to buy a bigger chuck
Great job. This is something I need to do soon, so it will help me get going without much worry.
You spelled consider wrong in the description. Great video.
Realy Nice work
Do something like colinfurze did with the rope launcher, he used his metal lathe a ton in that project. The only problem is it was all steel because he had to weld most of it but if you get an aluminum welder then I would love to see you do a similar project
Have you ever tried adding a little copper to your melt for better casting?
leaving the roundstock to cool naturally in a bucket of sand would improve the quality of the final aluminium, the slower the metal can cool the smaller the crystal structure of the material therefore improving the surface finish of any of your final products
does the metalergic stucture change when you rapid qwench like that
Hey there,
Very nice video, but what I would really like to see you make is a mini cannon with a fancy barrel (not aluminium).
I've just got my own lathe, and I plan to make one, but before I do I rather see what can you make of it.
Make Clickspring's fire piston, or a design of your own of course. You could also make some cool keychain gadgets, I've got a brass cup with threads etc it was a real cool small project on my lathe
you should build something that will let you push the flux to the bottom of the crucible in your furnace. doing this has improved the quality for me
You can also make a crucible that pours from the bottom (think gravy boat).
Are you sure the jaws aren't reversible? try opening the chuck as far as it will go, and the jaws will fall out. typically they will have two sets of numbers for the order that they are inserted into the chuck relative to the orientation of the jaws. Great video!
Absolutely sure. You can not reverse the jaws of a scroll (self-centering) chuck. For that reason most scroll chucks are supplied with two sets of jaws, one set for each direction. An independent 4-jaw "universal" chuck has reversible jaws. It is driven by a dedicated worm gear for each jaw. The scroll chuck has a spiral drive (tighter radius at the center than at the edge) requiring a very unique, precise shape to the teeth on the back of the jaws, curved in such a way that it will be tight at all points along the varied radius scroll. Turning it around means that the curves cut in the back of the jaws are directly opposed to the curve of the scroll drive gear.
Just get a 6" 4-jaw universal chuck for handling larger and square stock. Under $200 US, shipped. I believe your lathe has a 1-1/2"-8 threaded spindle, but you'll want to verify that before ordering.
+Jon Miller I own a proxxon pd230/e and it came with a 3 jaw self centering scroll chuck and the jaws are reversible.
I just change the order of the jaws from 1-2-3 to 3-2-1.
They do exist :-)
+orpantattoo Fascinating. It appears that their documentation is poor, so I can't see anything regarding how the chuck operates. Judging by the visible appearance of the chuck (more like a drill press Jacobs chuck than any other lathe chuck I've ever seen) it has a different mechanism than any I've seen before. What do the teeth on the actual jaws look like? Teeth on typical scroll chucks are curved to match the spiral drive gear ("scroll"). Because of that curve they can not be reversed. You would have to make teeth which are an intersection of the profiles for the two directions, which would mean that they are smaller, giving less bearing surface and therefore less strength, lower precision, and less available wear surface so they would also wear out faster. And they would be more difficult to machine, assuming that the goal is precision, making them most likely more expensive to produce than separate sets.
Thank you for sharing!
+Jon Miller the chuck is actually much like any other scroll chuck, the only "odd" thing about it is that the gears are external.
The teeth on the jaws have an oval shape so you're absolutely right about it beeing a crossection.
However I doubt it matters as the teeth have full contact on the side where the "spiral" drives them when holding the workpiece from the outside.
When holding something on the inside it does however have a smaller area of contact. But i rarely do that.
It is a VERY small lathe after all :-)
That type of scroll most probably wouldbn't work on a larger lathe like the 9 inch south bend the author has, which is why they don't exist in that size. Your lathe has a 2" swing (in American terms), his south bend has a 9" swing.
Throwing knifes with aluminium handles would be a good project to make with your lathe
also if you add arm and hammer ( WASHING SODA ) from grocery it makes it bond better
great job that looked great
diy forged aluminum next !!
maybe one day I hope . I'm sure it will be hard though .
Those are reversible Jaws, the should screw out, to be turned around, for larger stock.
No actually not, That is a scroll chuck, which means the teeth for the jaws are cut for working only one way. They teeth have a complex curve that matches the scroll that is turning when you tighten the chuck key. An independent 4 jaw chuck is what he really needs to open up real possibilities with that or any lathe. A little bit to learn and a bit harder to center, but a 4 jaw will allow much closer centering tolerances, and the ability to turn non round stock.
It's cheap, not free. It costs your time, and the power used to melt it. Worth doing though.
Totally jealous of your lathe ;)
Great filming. your video was really well put together!
fizzy drinks? new fav word
aluminum cans are pure aluminum ladders motor castings and such are alloys. the reason for so much slag is oxidization due to the melting practice flux etc. high end recovery from cans is ussually only around 68%
O.M.G THE PRONUNCIATION!!
It's okay to reuse the aluminum scraps from your lathe. The oil will just burn off and the other impurities will just float or sink to the bottom
Can you do a disc with a smaller disc attached to the middle so the discs have a common center? Then you can have the smaller disc in the lathe and the larger disc can be larger than the maximum diameter of what you can have now? You can cast it in green sand as you did some videos ago ...
If it works it works. I like the progress you make! :D
you should make a ice pick like diresta
while I've seen your videos before I've never paid attention to where you are located. However, unless it's just not sold there at all, you should be able to buy pure borax in your laundry isle at your local supermarket / shop. it should be the same as the stuff you bought from eBay and most likely cheaper.
once you pour the aluminium try compressing it with a weighted piston. It will give you a much better quality stock.
can you make a video showing how you made your custom cutters for the aluminum
thanks for the entertainment and information
great video.
Maybe you could turn out a round blade guard for a knife? I also am wondering if this technique could be used to make rectangular billets for milling progects.
you could do such suppressor baffles for guns it'd be really nice I like the idea of being self-reliant you never know when you need a gun suppressor
What about using dishwashing liquid as a degreaser and washing the oil off the scraps? (feed the mix through a colander to filter out the aluminum)
how well would it work if you used a disposable round steel cruible and just melted the scrap aluminum with lashing of flux then let it cool and extract aluminum?
basically used crucible as mould and skip the ingots stage, less energy will be used as not re-melting, thus will be even cheaper.
Can you use regular borax off the shelf?