Thanks for your help with this project! The pattern is actually resin--it's just hollow, with a lattice interior. If it were solid it would be well over a pound of resin, and I'd be skeptical I could get it fully cured to the center.
Been on this planet a little over 50 years and I've never seen the process of casting iron. So for me, this video was fascinating. Thank you very much. Excellent video!
I know what you mean I used to drive across I-55 several days a month going over to Jackson it is a rough and bumpy road. Good luck on your retirement!!
Hmm, retirement - that sounds nice: be like a kid again and play all day in the sandbox. O wait ... that's what you do right now 🤣 I don't know much about casting and was wondering why a 3 part mold, I must have missed the explanation while getting a cup of coffee, but it made so much sense in the end. Also the shrinkage at the bottom - I've seen things like this happening to plastic injection molded parts a lot.
First of all, nice work! Secondly, it seems to me if the Mini Mite mullers are so hard to find then it would be a perfect collaboration project to spin up again, either as a finished project or as a kit with cast components that need to be machined to complete. Certainly with the number of folks performing these activities these days they would sell. If nothing else selling plans to those on a very tight budget or wanting to do everything from scratch.
I’ve worked harder since retirement than I did at my job and I thought it tough at times. Hope you do get to fish a little more. God Bless for all your hard work on these vids. Not easy to get it all done.
Just watched clough42 video on making this pattern. I'm a retired patternmaker and just wanted to say a little about how you could have gotten a good casting the first time. Operating on 4 hours sleep, never good in a foundry 😉. Communication with the customer is good. The part was to be machined all around the perimeter, so no need to bottom gate. As you said at the end a single riser over the big mass would have worked better. Using a knockoff rise would make clean up easier. Side gate opposite the lettering would have worked. Not criticizing, just my observations. A redesign of the pattern could be looked at too.
That was super interesting to watch. It's nice to see that things don't always go as planned. That's so cool you posted this so we can see and learn about castings.
Brother, it's hard when you're a protectionist! I can't agree more. I'm not in the same business. I understand the chase for perfection. It's a chore the Lord only knows. Thanks for the videos, and knowledge to pass on!
Retired 15 years ago. Not sure where I ever found time to work. There has never been any shortage of things to do. Life is an adventure that no one survives. Wish you well.
Great video. I really enjoy when you try to fool the viewer. We all know the penny needs to go head down and looking to the right! Just fooling with you Clark, I hope the next few days go well as you head to semi-retirement. As a semi-retired guy myself I can tell you that you end up with less time to get things done once the regular job is done.
One of the best tools I ever bought for the shop was a burnz o matic TS8000 Self igniting torch. My original came with a fat max map gas tank, but I've used them on propane and they work fine. I make a base for it using an upside down pvc toilet flange. You have to warm it up the first time and press the tank into it. It's the only drawback to the taller torch head is they like to fall over but the base fixes that issue.
Exciting times Clarke! Good luck with your foundry business, looks like it's going to be a boomer! Looking forward to lots of Windy Hill Foundry videos, time permitting.
Snakes: It's monsoon season here in Arizona, and though I have been mowing like crazy, I can't keep up and the grass is tall in many areas. I'm constantly on the lookout for rattlers; especially the Mojaves. They are the nastiest snakes in our area. What a great score on the second muller!
Followed you from James channel and congratulations on your retirement as I will be doing the same on about the same day. Looking forward to watching more of your videos in the future.
I know you were being sarcastic but … you _are_ awesome! You still make it work, and make it work good, even when tired and the tools let you down! And if it’s not good enough, you make another one!
Brought up memories about my first summer job, other than on our farm. There had been dust at the receiving end of hay and straw, but the black from the foundry operation was something else. It took at least two months for the carbon dust to disappear from all my skin pores. I mean it was everywhere!
nice pattern, off to find the patternmaking video! Good luck with attempt #2, soon you'll be able to get a full night's sleep once you get yourself down to just 1 full time job 😃
Came here from Clough42 liked & subbed 👍👍 Hey for that the first casting you should turn it into something, like a lamp base or a pedestal for one of those complaint department grenades.
Clark, I commented on a video made in India when they were casting the axle hubs for a Fiat tractor. They had some very good molds for these, and they cast them from steel, and I couldn't believe the negative comments about cast 7 and only 5 will work. most assumed that the hubs were cast iron. I explained that when you start with steel, the casting will be steel. Finally a few realized their mistake.
If you found the lettering difficult it must be nigh on impossible for most of us so I would like to see how it’s done. As usual I leaned that F360 can do things that I was unaware existed. Looking forward to seeing the next stage.
Wishing you all the best for your (semi) retirement Clarke. I'm curious as to why you cut the keys in the bottom mould. Would the alignment pins in the flask not be enough?
Clark, has anyone ever tried to use a press to pack that sand? It does seem overly-difficult as far as packing goes, so I’m sure there are many other methods.
Very neat! I watch Clough’s video and came right here to see it cast. I don’t know much about casting other than bullets, but one question: how come you poured the excess iron on the ground instead of an ingot mold?
He pours so much that it's just as easy to pick up the iron flakes on the ground as it would be to cast an ingot. In fact it would probably take longer plus as he said the crucible wasn't set in the ring properly.
Do you do aluminum castings? I have a elipse that makes a 90* then goes to a 3.5” pipe . It’s for a 98 firebird. I have it designed in fusion 360 and have printed them out! Curious if you do this type of work that’d be reasonable priced.
I have no idea if this would be worth your time to do but make cast iron cups so your extra could be poured in the cast iron cups and the entire cup in for the next pore. Could make up sets of 4 and not cut the runners till after you fill the cups up but that's more work than picking it up off the floor.
What is the reason of all the little bubbles in the surface? Isn't there a way to avoid those? Also I think it would be better to put the pipe for feeders/risers in while filling in the sand, that way you don't have to push anything out of the way and damage the surface of the casting cavity.
Yes, there are ways to reduce or even completely avoid the bubbles. For one you can do vacuum casting, which will help to fill out the mold much better, or you can do diecasting (where a hydraulic piston injects the molten metal into the mold under high pressure, which produces a much denser casting and prevents any bubbles).
Are you retiring? If not what would a block of cast iron cost that's like the one you are casting in this video but with a flat surface where your logo is located you can put it somewhere on there though just need a way of clamping it to a table with c clamps.
I would recommend asking James. Typical business agreements would usually prevent a supplier, in this case the foundry, from selling a clients product.
clough42 addresses that in his video. yes, it could be machined, but the material cost would be much higher and you machine half of it off to get the final part, with cast its already close to final dimensions.
Good luck on your retirement. Now you will not have to work so hard.🤣 The surface of the casting looked like your sand was a little dry. What do I know?🤔
There's an old saying - " The dream is always better than the reality" I hope your decision works out, just moderate your mind and realize that now you are going to a job which pays the bills etc. and you are dreaming of getting home to do your foundry work. Next week, the foundry will be your job which must pay the bills and will no longer be the hobby you dream of going to.
Thanks for your help with this project! The pattern is actually resin--it's just hollow, with a lattice interior. If it were solid it would be well over a pound of resin, and I'd be skeptical I could get it fully cured to the center.
Been on this planet a little over 50 years and I've never seen the process of casting iron. So for me, this video was fascinating. Thank you very much. Excellent video!
I appreciate that you decided to recast the part. That part is so close to perfect, yet you are professional enough to chase that last 1% for James.
Enjoyed…very nice video production/discussion/demonstration….congrats on retirement
Haha, The penny joke cracked me up 😄. Thanks for the laugh.
Thanks for sharing enjoyed watching
Congratulation on Retiring soon. Been there since 2005 and had an LLC til 2016. Lasted a good 10 years. 🙂
I'm new here. I much regret not being here to learn long ago. Much appreciated!
A wonderful wise friend of mine once said " I only worked once, and I retired once. Retired is better !" Stay safe and live long.
This video is a much better learning tutorial with the hiccups and explanations. Thanks
I know what you mean I used to drive across I-55 several days a month going over to Jackson it is a rough and bumpy road. Good luck on your retirement!!
Hmm, retirement - that sounds nice: be like a kid again and play all day in the sandbox.
O wait ... that's what you do right now 🤣
I don't know much about casting and was wondering why a 3 part mold, I must have missed the explanation while getting a cup of coffee, but it made so much sense in the end. Also the shrinkage at the bottom - I've seen things like this happening to plastic injection molded parts a lot.
Cool, I just watched the Clough video! Great timing.
Best of luck to your new period in life!
First of all, nice work! Secondly, it seems to me if the Mini Mite mullers are so hard to find then it would be a perfect collaboration project to spin up again, either as a finished project or as a kit with cast components that need to be machined to complete. Certainly with the number of folks performing these activities these days they would sell. If nothing else selling plans to those on a very tight budget or wanting to do everything from scratch.
Came here from the Clough42 video. It was great watching the casting process, thanks for posting.
I’ve worked harder since retirement than I did at my job and I thought it tough at times. Hope you do get to fish a little more. God Bless for all your hard work on these vids. Not easy to get it all done.
Happy retirement!! Now you can get to work!!
Just watched clough42 video on making this pattern. I'm a retired patternmaker and just wanted to say a little about how you could have gotten a good casting the first time.
Operating on 4 hours sleep, never good in a foundry 😉.
Communication with the customer is good. The part was to be machined all around the perimeter, so no need to bottom gate.
As you said at the end a single riser over the big mass would have worked better. Using a knockoff rise would make clean up easier.
Side gate opposite the lettering would have worked.
Not criticizing, just my observations.
A redesign of the pattern could be looked at too.
"I'm so... awesome" Lol that cracked me up, i know the feeling
The algorithm introduced me to @Clough42 a couple of weeks ago.
James does great work.
That was super interesting to watch. It's nice to see that things don't always go as planned. That's so cool you posted this so we can see and learn about castings.
Brother, it's hard when you're a protectionist! I can't agree more. I'm not in the same business. I understand the chase for perfection. It's a chore the Lord only knows. Thanks for the videos, and knowledge to pass on!
Retired 15 years ago. Not sure where I ever found time to work. There has never been any shortage of things to do. Life is an adventure that no one survives. Wish you well.
It’s so cool when two of the channels I regularly watch collaborate on a thing :)thank you
Thanks for including the diagram, that cleared up a lot of assumptions on my end.
Great video. I really enjoy when you try to fool the viewer. We all know the penny needs to go head down and looking to the right! Just fooling with you Clark, I hope the next few days go well as you head to semi-retirement. As a semi-retired guy myself I can tell you that you end up with less time to get things done once the regular job is done.
Thanks for sharing!
One of the best tools I ever bought for the shop was a burnz o matic TS8000 Self igniting torch. My original came with a fat max map gas tank, but I've used them on propane and they work fine. I make a base for it using an upside down pvc toilet flange. You have to warm it up the first time and press the tank into it. It's the only drawback to the taller torch head is they like to fall over but the base fixes that issue.
Exciting times Clarke!
Good luck with your foundry business, looks like it's going to be a boomer!
Looking forward to lots of Windy Hill Foundry videos, time permitting.
Snakes: It's monsoon season here in Arizona, and though I have been mowing like crazy, I can't keep up and the grass is tall in many areas. I'm constantly on the lookout for rattlers; especially the Mojaves. They are the nastiest snakes in our area. What a great score on the second muller!
This is great. I remember sand casting in metal shop back in Jr High. Back when schools actually taught stuff.
Nice, congrats Clarke.
Followed you from James channel and congratulations on your retirement as I will be doing the same on about the same day. Looking forward to watching more of your videos in the future.
I love your process. Very cool craft.
here from clough42 video
loving your work
Hope you can enjoy your retirement. Now the real work begins. Best of luck on your future endeavors,
I am sure after good night sleep cast will look like million dollar .
Thanks, Clarke. Dollar did a nice job on that drawing, too.
I know you were being sarcastic but … you _are_ awesome! You still make it work, and make it work good, even when tired and the tools let you down! And if it’s not good enough, you make another one!
🙆🏻♂️Congratulations Clarke 🍻on your new Day Job 👨🏻🔧
Congratulations on your retirement, Clark. Hope you enjoy working in your new venture with more time to dedicate to it.
Thanks for sharing 👍 and congratulations on retirement
It is very interesting how this epic will end. Difficult job, many hidden nuances to consider 🙂
The spoiled casting would make a great base for a lamp or work light.
Brought up memories about my first summer job, other than on our farm. There had been dust at the receiving end of hay and straw, but the black from the foundry operation was something else. It took at least two months for the carbon dust to disappear from all my skin pores. I mean it was everywhere!
Congratulations on your retirement. Take care of yourself and your family.
Happy birthday Mr.
Pete
I love this. I would want something similar on my lathe. Can't wait to see the final cast.
Looking forward to seeing more of your videos
6:20 Those little "avalanches" are a perfect example of the mathematics of "Chaos Theory" in action.
Clough spent some time sanding and painting that pattern to make it come out of the mold but it also made your dust slide off easily too.
Congrats on the semiretirement!
Haa haa haaaa! "Lets make sure theres no snakes". Not a problem we have in the UK.
nice pattern, off to find the patternmaking video! Good luck with attempt #2, soon you'll be able to get a full night's sleep once you get yourself down to just 1 full time job 😃
th-cam.com/video/mTDWlXRYqwo/w-d-xo.html
Hope everything works out for you. Good video.
Came here from Clough42 liked & subbed 👍👍
Hey for that the first casting you should turn it into something, like a lamp base or a pedestal for one of those complaint department grenades.
Congratulations!!!!
congratulation on your retirement. I retired 8/2/18 and never looked back. Hard. to believe its been 4 years i. know you are going to enjoy !
Man, I love these colab vids! Congrat's on the semi retire! Now get back to work! ; ) subbed
I am new to the channel but not anymore. It was still a marvel to me.
Clark, I commented on a video made in India when they were casting the axle hubs for a Fiat tractor. They had some very good molds for these, and they cast them from steel, and I couldn't believe the negative comments about cast 7 and only 5 will work. most assumed that the hubs were cast iron. I explained that when you start with steel, the casting will be steel. Finally a few realized their mistake.
Those folks may have confused what happens when you remelt ductile iron scrap and cast it using traditional methods. That sequence yields gray iron.
THANKS, AND CONGRADS
Well done, your probably tripping around America now, but a professional knows what he has done incorrect. 😁
If you found the lettering difficult it must be nigh on impossible for most of us so I would like to see how it’s done. As usual I leaned that F360 can do things that I was unaware existed. Looking forward to seeing the next stage.
It's super fiddly because there are so many boundary conditions that break the chamfer and taper algorithms against curved surfaces.
Good luck in retirement, I am retired and loving it. Stay safe.
Wishing you all the best for your (semi) retirement Clarke. I'm curious as to why you cut the keys in the bottom mould. Would the alignment pins in the flask not be enough?
"I forgot the risers... I'm awesome!" 😆
Yeah, it's best to try again on that one.
Clark, has anyone ever tried to use a press to pack that sand? It does seem overly-difficult as far as packing goes, so I’m sure there are many other methods.
Some rare earth magnets in the output chute of the muller might catch some of the metal bits?
Congratulations on your retirement!
Very neat! I watch Clough’s video and came right here to see it cast. I don’t know much about casting other than bullets, but one question: how come you poured the excess iron on the ground instead of an ingot mold?
He pours so much that it's just as easy to pick up the iron flakes on the ground as it would be to cast an ingot. In fact it would probably take longer plus as he said the crucible wasn't set in the ring properly.
@@crystaldragon141 besides, like, it’s iron. Not exactly the most expensive metal, so if you lose a few bits… *shrug*.
Nice light show as you poured that one. Can you remelt the iron you dump out on the ground?
You're in Mississippi? No wonder I can understand you!
🤣
Congrats on your retirement! Now you can work hard on YOUR projects!
👏👏👏👏👏👏👏👏👏
Happy retirement!
Fuse?? I thought that is where the quarter goes.
Quarter? When I was a kid it was penny, you could buy a pack of 30A fuses for that quarter
Burnt down house only cost me a penny.
Do you do aluminum castings? I have a elipse that makes a 90* then goes to a 3.5” pipe . It’s for a 98 firebird. I have it designed in fusion 360 and have printed them out! Curious if you do this type of work that’d be reasonable priced.
I have no idea if this would be worth your time to do but make cast iron cups so your extra could be poured in the cast iron cups and the entire cup in for the next pore. Could make up sets of 4 and not cut the runners till after you fill the cups up but that's more work than picking it up off the floor.
I'm glad you can go on your own terms. You may look forward to four hours of sleep AFTER you "retire"!!
Just wondering why the crucible contents left from the pour are spilled on the floor instead of a ingot mold.
What is the reason of all the little bubbles in the surface? Isn't there a way to avoid those? Also I think it would be better to put the pipe for feeders/risers in while filling in the sand, that way you don't have to push anything out of the way and damage the surface of the casting cavity.
Yes, there are ways to reduce or even completely avoid the bubbles. For one you can do vacuum casting, which will help to fill out the mold much better, or you can do diecasting (where a hydraulic piston injects the molten metal into the mold under high pressure, which produces a much denser casting and prevents any bubbles).
Are you retiring? If not what would a block of cast iron cost that's like the one you are casting in this video but with a flat surface where your logo is located you can put it somewhere on there though just need a way of clamping it to a table with c clamps.
Are these going to be available to buy? I have the same lathe as James and I have wanted a solid toolpost for some time.
I would recommend asking James. Typical business agreements would usually prevent a supplier, in this case the foundry, from selling a clients product.
@@p.t.anderson1593 If there's demand, I'd be interested in making something like this happen.
@LimeyGuru - Looks like James is interested in making this happen. You should contact him...
Congrats on the retirement
@Windy Hill Foundry I want to do the same for my lathe; what were the labor hours and materials cost for this casting job?
Why do you dump it on the ground instead of casting ingots with it?
Can the castings have also more finer details? What does a casting like this cost?
Wouldn’t 3D machining a chunk of cast be easier?? No machining experience here so I’m curious.
clough42 addresses that in his video. yes, it could be machined, but the material cost would be much higher and you machine half of it off to get the final part, with cast its already close to final dimensions.
@@Corvus.2606 thank you for your reply! I’m learning!
With semi retirement you should be able get a good night's sleep and do your job better with no tired issues. Good luck
Looks like a bit of porousity on the surface? Is that from excess moisture in the sand?
👍👏👏👏
What day exactly was Mr Ptes birthday?
Clark, congratulations on your retirement.
Good luck on your retirement. Now you will not have to work so hard.🤣
The surface of the casting looked like your sand was a little dry. What do I know?🤔
There's an old saying - " The dream is always better than the reality"
I hope your decision works out, just moderate your mind and realize that now you are going to a job which pays the bills etc. and you are dreaming of getting home to do your foundry work. Next week, the foundry will be your job which must pay the bills and will no longer be the hobby you dream of going to.
Now I know why making a mold is so expensive.
why was the casting surface so granular WHF?