I am both amazed and very grateful as to how many of my subscribers and commenters are still around after what is an obscene wait of 2 years. Thank you all... Martin
im so glad to see you take on the you tube casting scene with some sound advice. its bean bugging me for so long, but i dont feel myself the authority to say to much.
Thanks for taking the time to make more videos. I have watched all your content and have learned much from your uploads. Many projects have been made thanks to the knowledge you have shared.
ViSc, Yep, its good to be back. I hope to do further videos in this line although I might ease up on the error pointing out and concentrate on the right way a bit more 😊.... Martin
Delighted to see you're back and able to make videos again. Really appreciate the time you take to share your knowledge with us. Missed you during the past year or so. Hope your health is improving!
Eric, Yes, its nice to put a video out again. I am limited though to the sort of video that does not require much physical effort as so far health remains the same 😥. Some chance for improvement in the near future - maybe possibly perhaps hopefully... Martyin
@@johnkelly7264 Yes, this has been suggested before and I have had discussions with one or two people but nothing ever seems to quite come of it. I am amenable to the idea but there are difficulties - it is much easier to show someone how to do something that it is just to tell them. There are things like getting the sand ready the day before helper(s) turn up and currently I am not able to do this as it is physically demanding. At the moment I doubt I could last for the 3 plus hours that a typical moulding session takes without at least an hours rest. But if anyone out there is serious about wanting to be a helper and lives close enough to Croydon Melbourne Australia then I would love to hear from you.... Martin
Flinstone. I will try to keep the posts coming. To be honest the turd polishers of this world are not my target audience for I fear they are not much interested in what I have to say. Its more those trying to do a good job and often frustrated by the difficulties and foibles of the process. But all are welcome to use what I say.... Martin
Thomas, I used to be guilty of at least some of them too but the first step to getting better is to admit any mistakes clearly you are past this stage - well done..... Martin
D. Jeff, It is good to be posting and I have to admit that it is one of the better castings I have done - that particular style of throttle body finished well.... Martin
Jim, Yes, its good to be at it again even if in only a limited way. Must admit I have never really thought of myself as wise just as a person who has been doing this for a while - a long while.... Martin
So good to see you upload! I find it funny that I recognise almost every source for these mistake images, however I am proud to say I no longer watch any of their channels.
Why not watch them !? After this video of Martin, you will know where they are wrong. But that doesn't mean they don't show useful things. I also recognized many of the sources ... I am glad that Martin is here again and gives us new knowledge!
Lancer, Evgeni, I watch them -well some of them - from time to time, sometimes just for comedy relief 😊 but also to see if they are improving and I am pleased to say that some of them at least are.... Martin
YOU'RE BACK!!! We so missed you and your brilliant videos. Thank you so much! Please sir, can we have some more videos? I hope you and yours are safe and well.
I found this video extremely useful. While I generally seek out "what to do", I find "what not to do" perhaps more useful! I'm quite glad that you're still around, as well.
elitearbor, Thank you for saying so. I do plan some more videos of the "what to do" kind. I am a bit uncomfortable with the "what not to do" type as it gets very close to denigrating other foundry video makers so another one of that type while possible is as fair way off - it takes some time to collect examples too, even though there are lots out there 😱 Putting them into a watchable video is a long winded process too, that video took about 3 months to do... Martin
Loved it and learned a bit in the making, thank you. I've missed your videos. Can't wait till you explain more on the points you've mentioned. Oh and yes, what a beautiful casting example of surface finish, that's gorgeous.
Cobrin, Well I am back and hopefully I will be able to amplify some of the points in the video and mention a few more too - there are a lot more although many are quite subtle.... Martin
You’ve got to appreciate a straight talking Australia 👍. Lessons learned and the proof of your skills and experience is evident in that stunning throttle body. I hope you filmed them casting of that component 🤞🏼
North, Yep, a spade is a spade and all that. I did film the casting of that throttle body. There is a two part series called "Casting the SR20 throttle body part 1" th-cam.com/video/NXtTfJ-FG70/w-d-xo.html And "Casting the SR20 throttle body part 2" th-cam.com/video/r4P8kctZOkI/w-d-xo.html .... Martin
I feel like I've been in the headmaster's office. I expected to see myself pop up as an example of every mistake discussed! Thanks for helping to stop the folly of us muggles Martin.
Flower, From Muggles to Wizards takes time and practice, many many years in my case just to get this far along. there is always further to go! I guess I am just trying to shorten the journey for others.... Martin PS You never know maybe you will appear in episode 2 😊
Welcome back Martin, here's hoping you and your family and friends are all doing good, and that we'll get many more videos from you for many more years. You're such a treasure! Greetings from France.
Soda, Greetings from the great wide brown land down under. Its good to be back - family is well and thank you for asking, but me - eh - not so much, a lot of back pain on standing, makes it damn hard to do anything. A number of videos planed but its just the suffering through the doing of them. Not so bad if like this one it can be done almost all sitting down but to stand at the moulding bench is a bit of a stretch. Possibly another attempt at pain mitigation surgery in the near future - last two attempts have failed and I do not wish to resort to opiates... Martin
Your favourite TH-camrs are like old friends. You miss them when their not there. You worry about them. You hope they are doing OK. But when they pop back into your life, it brings a smile to your face and it brings you joy. And you certainly are one of my (and many others) favourite. Not just because of the content you create and the knowledge you share but because you care enough to share it with your TH-cam family. I may never use any of the information you have provided but I have thoroughly enjoyed all your videos because I love watching a master at work. Stay well old mate (or at least as well as you can).
Jack, "Old friends" yes, that is about right. If I have made even one of your days a little happier then I am happy. Doing my best to stay as well as I am (which is not very) but old age is making it damn difficult... Martin
Let me start by saying… please never leave us again! Glad to see you back sir, and I’d love to see you make some new castings! I miss your videos! Oh man, I loved this video, you had me rolling, your commentary is the best!!! I feel honored for having some of my mistake clips make your video! I could go on and on for days, while I’m no casting master like you(I just do it for fun and hobby a few hours a week(so I’ll never be to your level)) you are an inspiration and a true master! I’d love to come spend a week with you and just watch you in action if I could. You’re the best Martin! PS- if you ever feel like doing a voice over for one of my videos and really roast me down to size, and send it to me, I’d get the biggest kick out of that.
Growing, Thank you for your rather nice comment. I had great trepidation in releasing this video as I feared for a lot of bad reaction, wonderfully I have to report that I have not had even one bad comment🤗. I did try to make the - ahem - borrowed clips as anonymous as possible but it was obvious that where they came from would not be that hard to determine. However, for four reasons I will demur on your voice over idea. 1: Ripping apart just one persons single video is just a bit too personal. 2: I have in the past provided information like that (sort of) privately to people just for their own private use, but they have used it to release "50 ways to leave your bad castings behind" videos as though they were an expert even though they have made at most a handful of very ordinary castings. In doing this they have released information before I had a chance too, thus robbing me of many video ideas. This has happened to me several times and several times bitten most definitely very shy. This is very mean of me I know but I too have a right to a little YT success 3. Because of 2 any critic would have to be a released video on my part i.e. public. To "attack" another youtuber so publicly and completely is not my way. To cause them embarrassment in front of other youtubers (most of whom are equally as bad I might add) is not something I wish to do 4. I looked at two of your videos - your latest melting down aluminium wire and one where you melt down a large ingot of (the wrong) zinc alloy to make a hideously bad mould rammer design. At a quick look in the first of these there was 15 mistakes in the second about 30! Many were only small mistakes but some were big....... Martin
@@olfoundryman8418 Thank you for the reply. I totally understand you not wanting to do a funny roasting voice over, although I still think it’s a great idea, you could totally preface the video that I asked you to do it and post it on your channel(And I only mentioned send it to me, not for me to sell you out and post it myself like you said others have burned you in the past, but I was meaning for my own private enjoyment to cherish) but I’d share the hell out of it if you ever did. From your #2 last sentence, Its not mean of you, I’m surprised more people aren’t subscribed and watch your videos, and I’ve never given you a shout out yet because, as you can tell, my techniques that I’ve tried to teach myself and “learn by doing” would be a discredit to you 🙂 -although I should ACTUALLY try some casting tips from you(to better myself) and add a title that I learned it from you and tell people to check out your channel. Maybe I’ll try that this weekend 🤔 I’m a comedian at heart, so the idea makes me giddy, and I’m old school so nothing hurts my feelings like that. I even had to re-read #4 in your voice(which is the best, not joking about that) and I can picture an ‘Ozzy man reviews’ style video of the zinc sand rammer video. “Aaannnndddd we start right off the bat with the worst design of a sand rammer you can possibly choose. He’d have a better bit of luck with it if he just shoved it up his tailpipe. Oh wonderful, he’s chosen a zinc alloy, albeit the wrong zinc, but by the looks of his “shop” if you want to call it that, he obviously can’t afford a quality zinc alloy. I mean come on, is that plywood on top of a shelving rack??” 😂 Sorry, I’m a little kid at heart and think that kind of stuff is funny. Anyway, if you ever change your mind send me an email thegrowingstack@gmail.com, aside from all of this I’d love to be able to email you personally and call you a friend. Sorry for the novel, you’re the best Martin, have a great weekend!
I really appreciate your honest and candid manner to WHS and your willingness to educate. Cheers mate. Oh and thanks to "Vogman" re Lost foam casting who put me on to your channel.
glen, Thanks for your comment. I hate to see foundry "done wrong" so hence this rather feeble effort to point out some of the traps people fall into. My thanks to VOG for the referral. We used to be in regular contact but sadly out relationship sort of drifted apart.... Martin
i am so sorry to hear of the drift. you both offer so much valuable content. I am learning for a disability client of mine so I can teach her and myself from the master's such as yourself. We truly appreciate your guidance. Thank you.
Good to see you putting a video up again. Following your advice from a couple of years ago, my castings have improved a lot, but I sill have a long way to go. I am still making mistakes that would be very difficult to identify without videos like this to help. Thanks again.
Ian, Good to hear that your work is improving. I am happy to think that my videos may have helped with that. We all sometimes need help identifying what went wrong. I have often noticed in some videos that both the videoer and the commentators get it badly wrong when identifying the cause and cure of a problem. At times I get stumped too, and have to begin a literature and peer search for answers.. Martin
Those 4 little pulleys on the enormous sprue were mine, cheers chap, only just discovered your channel it's very useful and I'm honored to be an example of what not to do.
Turbo, Do you mean the 4 little wheels at 2.42? While you may have done something similar these ones were not yours. I won't let on who did them other than to say he is a fellow countryman of yours who has been on YT for quite some time. I see that you are a material engineer - well I guess that sort of makes two of us - I am a metallurgist. You should enjoy those books of John Campbell's that I mentioned in the video. The info in them blows the cobwebs right off the 6000 year old technology still in use by way too many foundries..... Martin
@@olfoundryman8418 Martin you are of course correct, my similar pulleys, sand and excessive flashing stuck with me. I'll certainly keep my eyes peeled for those titles and continue my education with your videos, this one alone answered many questions around my own failures in both greensand and permanent. Professionally I'm a maintenance engineer but at home I'm a life long student of material science, it gives me a lot more leeway with f'ups. James.
Great to see you back Martin! I've been an occasional caster for over a decade. When I started out I was probably making all of the mistakes you outline here, over the last 5 years or so I've been incorporating the methods you show on TH-cam into my work, and I can definitely see the improvement. I still have some way to go and I'm sure if you were to see my videos you could point out a number of errors (some admittedly due to my own laziness). Your videos are my (and I'm sure many others) favourite source of casting information, I know you've been suffering with health problems and it may be a while before we see you back at the moulding bench, but more videos in this type of format would be equally welcome. Cheers from sunny England!
Andys, Greetings back from a cold powerless Melbourne where even if there was power you could not afford it. I will checkout some more of your videos (have seen some - was sent to your channel by smallcnclathes) who knows what I might find. He He😊. If I have been of help to you I am well pleased. Mistakes are of course part of the process... Martin
Aaron, I can not guarantee that I can get you doing work like that first up but we must put our heads together to see what we can come up with re lessons - If you can do all the physical stuff while I sit on a chair and bark orders we might be able to get something done. Start thinking about something that you would like to cast as a first up.... Martin
I've actually started implementing some of the mold designs (feeders, risers, etc) you show into rubber molds meant for resin casting, and it's resulted in better castings all-around. It takes a little more time to make, but considering the time I'd otherwise spend grinding resin, it's worth it.
Thomas, Interesting. Is it because of less air entrainment do you think? I looked but you do not seem to have any videos up about this process - a pity - I would like to have seen some. Its the same with metal much better to cast it right and therefore not have to grind it lots... Martin
James, Yes, indeed there was a bit of a learning curve - initially very steep and a slow still continuing grind from then on. Part of my idea with a video like this is to nudge people a little further along the curve and thus save them some time - I mean, why should everyone have to reinvent the wheel.... Martin
Good to see you back again Martin. It has been a confusing two years for everyone, so it is time to start moving forward again. Mark from Melbourne Australia
Thank you Martin , Just to let people know that Martins castings are of high quality. A man with many years of Experience, I have use his castings in the past , very clean and great Machinability,, Martin you have Been. a great Mentor and a Great Friend to many people, Just want to say Thank You..
I second that, as a customer I have used thousands of Martin’s casting both sand and gravity diecast. Quality was never an issue and always machinable on my small cnc lathes, which says a lot.
Craig, Sharing is my pleasure. Sadly the health problems are still much the same hence this was an "inactive" video. It may be a while before I can return to the moulding bench.... Martin
I have never made a casting and I may never, but I absolutely love your channel because of the detail. I sure have missed you thanks for coming back. Knowledge is power.
Paul, Come on get out there and make a casting 😊 its a skill of great use and a lot of fun (sometimes😊) You have the knowledge - use it. But use it or not thanks for watching.... Martin
@@olfoundryman8418 You're right. When I purchased my TIG welder now I use it way more than I thought. I'll put casting on my short list. Thank you for your time and putting your information into our hands.
I've nearly finished reading all of John's books and I've got to agree with you, they are a pretty hard slog. However, as you clearly demonstrated with that gorgeous casting, the proof of John's techniques are in the end product.
Dean, All of them - WOW that's quite a effort well done. My mathematics is not really up to the task. I find myself reading and rereading them at every opportunity - doctors waiting rooms etc anywhere 15 or so minutes is available. I often refer to them when problems arise or a new job comes up - often now on behalf of someone else of course...Martin
jam-packet full of expertise =) Thank you for sharing this bit of your wealth of knowledge on the matter! You did sound a bit angry at times... I remember a very serene image that I got of you from your older casting videos. Don't let the silliness of dumb young blokes get to your heart! I always love to see your videos, because there isn't a single one that didn't teach me new knowledge :)
I think Luke that is passion rather than anger. Martin is quite passionate about foundry work and hates to see folks doing it badly when with a little effort, huge improvements can be made.
@@smallcnclathes Yes, I'm sure it is. I don't think I meant actual anger, more like his professional pride (fully deserved) causing some vicarious shame or appalled disbelief that they would broadcast such mistakes out on the internet as proper practice. I've been following him for years now, 6 or 7 I believe, and the videos he puts up are not only always teaching me something, but watching an experienced craftsman at work has always been oddly satisfying for me.
Luke, Basically smallcnc is right, its passion and love for the "genteel" arts of foundry. I do however admit to occasional fits of a cross between amusement, amazement, and yes anger at what I see some do to those arts. Its the people who are have no interest in doing it right and seem only interested in how many views and subs they get that do try my patience. People, who like yourself, learn something with each video are my salvation... Martin
@@olfoundryman8418 And you are ours... Seeing your videos reminds me how I want to excel at a trade too. My situation makes it very easy to slip into a passive state, and watching videos like yours actually stimulates the creative part of me. So aside from the knowledge base that teaches me new techniques or solutions, these videos are also a kick in the butt to get off my behind and get my hands dirty =))
Martin, Glad to see you back. I'm glad you are repeating information regarding Campbell books. Some of us are listening to what you have been saying. I followed your advice, and bought his complete textbook. There is so much information in there, for everyone. The section on sprue gate and metal velocity during a pour. I hope you can find something that can help with the back pain, we are rooting for you and your pain-free future.
Mr Eric, You bought the big book - you are a glutton for punishment! Even as an experienced foundryman and a qualified Metallurgist there are parts of it that I struggle with but it is a great resource. I go to see a surgeon about the possibility of pain mitigation surgery (tries one and two failed) in a couple of days - maybe I will get lucky this time. Pain free is most unlikely but a good reduction is a possibility...Martin
Garry, Forget that "down the track" just get out there and do it. If I have helped nudge you in that direction and provided some useful info then I am well pleased... Martin
You my friend have helped me out immensely and I thank you for your years of hard work and knowledge that you have acquired to be able to do so.thank you again.
Hello Martin, I am so glad to see you here again after such a long time. I hope that you are well. Your advice is always welcome. Thanks to you I have been able to make some parts for my old EBRO tractor (Fordson Super Major design made in Spain) Greetings from Galicia, Spain
Pedro, Greetings back to you from Melbourne Australia. I am glad that my advice is welcome and that it has proved useful with the tractor, And thank you for saying so...Martin
Great to see you are back, you have the viewer's respect and loyalty for the information and the way it is presented. As I am sure everyone agrees great job, a true treasure trove of knowledge.
Metal, Sadly to many copy the mistake makers and thus not only perpetuate the mistakes themselves but spread them on to still others who mistakenly think that those they are copying have it right. - I just had to do something to all least correct a few of the worst of the errors.... Martin
thank you so Much!!! finally another person pointing out the terrible practices that are being made popular by the TH-cam algorithm. I don't feel alone anymore
Henry, You are not really alone! There are some good foundrymen out there. they are just quite about it. Take Kelly Coffield the lost foam genius or d laszlo the steadiest pair of hands in the moulding game, watch him with composite petrobond/greensand work - just brilliant. Or Luckygen1001 a 40 plus year cast iron veteran, like me he speaks his truth. But yes, YT has a lot to answer for when it comes to spreading misinformation, nothing that they can do about it though. Its up to the viewer to sort the chalk from the cheese, assuming he knows the difference of course and sadly, he often does not.... Martin
Thank you for these absolute gems of knowledge! It's good to see someone on youtube who approaches casting the good way.- Gábor (a guy who is doing academic research on oxide films)
Gabor, Thank you for your comment. Yes, I try to follow the great Guru John Campbell although I have many questions some of which relate to how one can and how far one should adapt his work to the small scale moulds that we hobbyists work with. I wish I was young enough and in the right position to do the sort of research work that you are involved in. The foundry industry needs all the help it can get from people like yourself. Have you published any of your work - I am always keen to learn more and read all I can find..... Martin
Super helpful video Martin. I didn't make your hall of shame this time, which was a good thing. I am trying to implememnt your lessons. Keep this stuff coming.
Rotary, Hmm, maybe I should check out your channel to see if I can find some suitable slip up to highlight 😊 Ah yes, that Beatles fail looks to have the odd - ahem - hiccup. That spherical bottom pouring basin for example - the shape just makes the metal ricochet out if you try to keep it appropriately full during a pour - hardly mattered in this case with the blocked sprue and all (happens to all of us). Still we learn much more from our less successful efforts than from our great successes. Hang in there.... Martin
thedude, You have hit upon one of the reasons for undertaking foundry as a hobby - the ability to make bits that are otherwise unobtainable or to expensive. It can be a very rewarding thing......Martin
Great to see another video from you again. Thank you for taking the time to pass on your knowledge from all the years of your experience in getting great results! I look forward to this series of videos.
Martin, always a pleasure to hear your well experienced and solid advice. There are so many atrocious casting video's out there and beginners follow using the same atrocious failing techniques. Your advice is spot on, read and understand the materials you are working with and above all observe and analyse not only what goes wrong with your castings but what went right and develop your rules accordingly. Had a chat with Dave at Outlaw Castings at Lake Goldsmith, he is doing some fine work in his set-up, great to see someone who knows what he is doing passing on his experience in his casting demonstrations. Cam
Cam, It was actually a few of those bad videos that got me on to YT, I felt the compulsion to try and counteract the bad info out there. Sadly my success rate had not been all that I might wish for but clearly I am reaching some people including I think those that actually want to improve rather than just get more views... Martin
Keith, Horses water yes, indeed. The problem is that some "horses" prefer to just stick in the past or are content with views and do not care about good castings.... Martin
Martin, Great to see you posting a new video. I like the rest of your followers/subscribers look forward to future videos whenever you are able to post them. From the shores of the Chesapeake Bay in Maryland, USA thank you for sharing your knowledge and wisdom
gull, Yes, it was nice to put a new video out. Md you say - hey, we might be related😊 my earliest know male line ancestor arrived in MD 1677 as an 8 year old indentured servant He prospered, taking land right on the Md Pa border, at that time disputed territory. Greetings back from Melbourne Australia..... Martin
Axe man, Lancer, "one shot to be perfect" - hmm I wish it were so. Every new job has its challenges and I often come up with two or three scenarios to cast the part, try them all and then pick/modify the most successful. Those throttle bodies were perfected over many designs and many years - you just have to keep plugging away.... Martin
The Master has returned! And in full form! TH-cam, prepared to get schooled. Really warms my heart to see you are back Martin. Hope your health is treating you a bit better these days. I can not wait for more of your mentoring. All the best, Jaime from the Blue Mountains.
Jamie, Blue Mountains - nice spot. Health no better but I can manage videos like this one where not so much physical effort and little standing up is required. Hopefully I have more on the way.... Martin
2 years of bated breath wondering if you would ever share more if your casting wisdom. Thank You for returning to further our knowledge of this industry.
Skip, Experience is not the only teacher out there but it sure does a good job of it. Just about all of the errors mentioned were down solely to inexperience... Martin
David, Yes, its good to be back and I am trying to finish the moulding box series but back pain after just a few minutes standing is making it very difficult..... martin
@@olfoundryman8418 I've been having serious back pains myself for the last few years and I now try avoid eating tomatoes and eat more coleslaw (the apple-cider recipe) or Sauerkraut.
@@DavidMullins1 Thanks for the thought but sadly my back is well beyond any easy means of pain relief. I saw a back surgeon today and he is going to implant a nerve stimulation device that MIGHT (50:50 chance) reduce the pain level to where maybe I can get to do what I want regarding making more videos etc. Anything to avoid strong (addictive 😱) pain meds... Martin
Big thank you. I think most of us started out with "how to" on youtube. We really need "how not to" every now and then to learn to correct our mistakes. Please keep teaching. We will learn.
G’day Martin. It’s Aaron, this is my other channel. Your video was that good I had to come over on this channel to like and comment also. Mate you had me in stitches through that video with some of those comments. I’m rolling on the floor laughing. Hope you’re well mate look after yourself all the best Aaron
Aaron, Yeah, sometimes I have no other reaction than laughter and sometimes that's all you can do in reply to some of the stuff I have seen If I did not laugh I would cry..... Martin
Oh this entire video is beautiful. I miss the lecture type format of old youtube videos. I'm taking on the gingery machine tools challenge as my first casting projects. I wanted to dive in headfirst and learn from other people's experience. Im 100 percent not good at it at all, but im learning through watching videos like yours.
Doble, Thanks very much for your wonder full comment - I could take comments like that all day! I don't meant to be a bit of a downer but I am not much impressed with the gingery machine tools. The problem is that aluminum has very little ability to damp out vibrations. There is a good reason why cast iron is used for machine tools and that is its excellent vibration damping ability. With aluminium your will get a lot of trouble with chatter and likely have to take small slow cuts. Still, I guess its a good learning exercise..... Martin
May God give you all the best Mr. Martin. I have a lot of difficulties since I want to change the method of my cake mould aluminium production, from sand to permanent mould. God direct me to your channel youtube, big thanks. Sometimes I think I want to learn directly to you. May God give you All The Best, ameen. Big thanks Mr. Martin
So glad to tap into your wisdom yet again Martin. Was getting worried as so long between posts, now this is superb info which I will take on board. Many thanks
Allan, Yes, it was a long time - too long. I do have more planned but at the moment I have to find topics that I can cover without getting too hands on at the moulding bench as that is currently beyond me. There was a fair bit more I could have included but examples available were a bit to obvious as to there originator. Also of course there was a bit of a limit on video length - I did no want to go on for hours 😊.... Martin
You are a most welcome return to my TH-cam diet Martin, welcome back. I am 25 years into retirement and have many yet unfulfilled aspirations, one being to produce some useful castings. I hope that you have best ergonomic setup at the computer because many hours editing videos can be hard on the spine. Hope the treatment is successful and that you successfully navigate this Covid nightmare that our beloved city has become. Stay warm.
Penyll, It is good to be back. 25 years into retirement - wow! You must be even older than me -I hope that you are in better condition 😊. While Covid has been quite an issue I think it the least of our cities problems - massive gov debt, politicians treating us like mushrooms, suburban infill, our children being taught absolute self denigrating rubbish. explosion of Woke, anti-car practices, treasonous politicians removing and/or denigrating our flag. - Stay warm - well , yes if only I could afford the gas or electricity - assuming of course that it was available. I could go on but had better get of my soap box before I stroke out 😊... Martin
@@olfoundryman8418 I just know that my small iron/bronze foundry efforts have been advanced significantly thanks to your sharing. It is very much appreciated.
I came across one of your vids about a month ago and learned a lot. More than Inever learned from the professionals around me wben they're on the high horse. I don't cast but I was enthralled but your matter of factness. Its been on my mind for 30years tho. I'm glad I waited and didn't become a turd polisher. There are toooooo many of those folks in the world.
Slinky, Yep, YT is full of turd polishers - their only interest is in making a video it doesn't matter what about as long as it's a video. IMHO a waste of space, time, and fuel that contributes nothing to the wider knowledge of foundry. 30 years? Time you got on with it 😊.... Martin
So happy to see another of your videos! Thank you so much for sharing your experience and investing the time to make these wonderfully informative videos. You are truly a master and my hobby has benefitted greatly. Thank you, thank you, thank you!!
thinge27, It is good to be back but things really are no better with me, As it stands the moulding bench is out of reach - there is a chance though ... maybe.... Martin
Martin please keep them coming! You are an inspiration. I am just about to get my home made foundry online. I am attempting to cast a bellhousing for my little Lotus project. I hope to have some pictures to share soon :)
I am extremely guilty of making many of the mistakes you point out here when I first started. However, after Perry recommended your channel to his viewers, and having gone through your videos, taking notes and video times for reference, and taking the time to order Professor Campbell’s books for reading and studying, I have learned quite a bit and am slowly gaining experience in my casting attempts. I love that you really hit on the safety aspect of casting, particularly on one individual who thinks that relying on the Leidonfrost effect to keep him safe is acceptable. I’d say my biggest improvement to be made is in making a proper sized pouring shank for crucible. It took me over a month to make a decent set of simple lifting tongs, so I am still working on getting a good pouring shank made. Great to see you upload and call out the improper practices you see, while helping us newbies understand why these things can be dangerous or why they’re important to do right. While I’ll probably never make more than artsy pieces with less-than-favorable aluminum alloys, I think that having the opportunity to increase knowledge of foundry work, the science behind proper pouring practices and techniques, and good safety practices, even for just a backyard hobbyist, is critical for future generations who get in to this as a hobby.
Super, We all make mistakes particularly when starting out. What matters I think is that we learn as we go along and not make quite so many. Personally, I have little faith in the Leidonfrost effect. The initial "hit" of a splash on the skin will break through any such effect - sure it may come into play in the few following seconds but the damage will be done, and as for radiant heat it offers no protection from that. And radiant heat has got my pants to smoke and burnt me through a layer of clothing - the man is an idiot. The right tools are essential without them it is just not possible to do a decent pour. Nothing wrong with "artsy" pieces and the experience making them will stand you in good stead if - with appropriate alloy changes - you ever need to make a true engineering casting... Martin
Brian, The sad thing was that I could have put hours worth of such examples in. Many areas that I wanted to get into I just did not have time for. Stay tuned as in future videos I hope to expand things.... Martin
Andy, Whoop Whoop indeed! Hopefully I will have some more to follow and with luck they will not take the months to do that this one did - I just have to get through replying to all these comments first 😊 ... martin
Amalgamous, Well I am sort of back! That level took a fair bit of practice but more than that it took a constantly questioning outlook - how can I do it better? (And quicker - I had to make a living after all). If you always look for improvements with an open mind (sadly a rare thing amongst foundrymen) you wil get there.... Martin
Danny, Aren't beer kegs wonderful things. I have one as a quench tank and another as a fuel tank, they sure make good furnace surrounds too. Take it slow when you start, easy things to begin with and work up from there as your experience and confidence grows - there is a lot to get your head around at first. Good luck... Martin
I am always excited when I see that you have posted a new video. I'm glad that you still have more videos planned even though they will not include actual casting. While I have learned much from your casting videos, I welcome any new videos about the things you have learned about casting. When I was in school we had "Shop" classes to teach hands on skills. I remember one term was metal working, that included sheet metal forming and aluminum casting. I ended up taking taking an electronic technology course in college and was fortunate to have worked for electronic manufacturing companies. The first year was in the testing department of a large telecom factory. The next 12 years was at a tiny electronic shop where I we had our own line of alarm panels, and we also did some custom design and manufacturing for other small companies. I did design, purchasing, assembly, testing, customer support. I learned a lot there. I then moved to a small (but bigger) electronic manufacturer as the senior electronic designer. After 25 years there I finally retired last month. I have always been interested in design and manufacturing processes. Working for small companies, I didn't get paid a lot, but I was involved in all aspects of product creation. I have a small workshop at home (lathe, mill, etc.) and had used it often in project development for work. About fifteen years ago I made myself a small electric furnace to do some metal casting. I decided to start with zinc based metal due to the lower melting temperature and because I could get away with using welded steel pipe (thick walled) as the crucible. The first attempt was pretty spectacular, due to the sand being too wet. The second was a little better but still too wet. The third attempt went pretty good. I had a 125mm injection molded timing gear as a pattern. I knew the draft on the part was insufficient, and the outside perimeter flange was too thin, but I just wanted to cast something. Because of the lack of draft I think I had a problem with one edge contacting the other half of the mold when I was reassembling it after removing the pattern. A little shifting of the sand. There was some shrinkage in the center. I plugged the drive shaft hole in my pattern and I did not provide a riser. There also was some shrinkage on the inside of the rim where I had my gate cut. It had a little rough finish, but I was surprised at the level of detail retained. There was a small circular paper label on the inside surface and it is clearly present in the cast part, along with the molded in raised part numbers. Unfortunately that was the end of my experiments in casting until last year. I did a couple of items and incorporated many of the things I learned watching your videos. Still there were flaws but every flaw was explainable. And a learning experience. With my approaching retirement I decided to purchase a few different size crucibles so that I can cast aluminum. Only the smallest size will fit into my existing electric furnace. (4"x4"x9" inside dimensions, made for my 3.5" o.d. steel pipe) I have made up simple, but proper, lift out tongs and a pouring shank for the new crucible. I hope to give them a try withing the next couple of weeks. As I stated, my current small furnace is electric. I live in Canada in an area where half the year is cold to very cold. This is one of the reasons I prefer an electric furnace. In my basement I have a small welding chamber that I can use in the winter. It has piping and a fan to exhaust welding fumes, with a minimum of heat being pumped out the building. (with -20°C air replacing it) I still have enough insulating firebrick to make a bigger electric furnace but I am concerned that it will take too long to get the aluminum from melting temperature to pouring temperature. Over the years I have been collecting aluminum at work. When we scrapped sheet 3003 aluminum for discontinued parts I would collect it. I also collected a lot of heatsinks, 6063 extrusions, from returned or scrapped production. I had assumed that I would sell off the aluminum and replace it with proper alloys for casting. A couple of months ago I was surprised when I came across some research papers where 6063 was used for casting tests. Investigation of Mechanical Properties of Aluminium Cast Alloy (6063) By Varying Chemical Composition www.irjet.net/archives/V5/i4/IRJET-V5I4689.pdf Effect of casting mould on mechanical properties of 6063 Aluminum alloy jestec.taylors.edu.my/Vol%207%20Issue%201%20February%2012/Vol_7_1_089_096_WASIU%20AJIBOLA%20AYOOLA.pdf Modelling the Mechanical Attributes (Roughness, Strength, and Hardness) of Al-alloy A356 during Sand Casting (one compared alloy was 6063 aluminum) www.ncbi.nlm.nih.gov/pmc/articles/PMC7040807/ Because of these I decided to give the 6063 I have a try before bringing it to a scrap yard. When it comes to casting videos I like they never seem to include putting a hot ingot on a block of ice, or into a bucket of water in a plastic pail. What I want to see is a part being made. I don't care for metal muffins or pouring molten metal into water or ant hills. What I like to see is the pattern of the part. Why it was made the way it was, if there were any casting challenges. Cores for example. How it was gated and risers used. Ramming sand (unless special precautions need to be made) and pouring metal generally I skip. I like to see the cast part and the attached gating and risers. Anything that would explain why the pour went well, and why it didn't. When I look at a part to be cast I think about solidification, where and the path, until solidification. I appreciate the Oldfoundryman videos, and a few other channels that produce quality casting content. I hope that when I ever make my own videos that I would provide good informative content. (sorry about the length)
Rudy, I am guessing that you are from the "French" part of Canada - not that it matters of course. I know of the Canadian cold - not first hand but both my parents were Canadian, Mum from Winnipeg, Dad from Agassiz BC and both often spoke of the cold and how glad they were to be in a warmer climate 😊. But I would love to be able to visit Canada as it looks to be a truly picturesque place. Re 6063 those articles seem to give a confusing idea of the hardness with readings from 30 Hb to 80 Hb. At 30 the material would be like chewing gum and thus unmachinable 80 would machine quite well. However 6063 does not have any significant eutectic in its structure and thus you will struggle to get a good sound casting with it - you will be making it hard on yourself by using it. My suggestion is that you sell the 6063 to a scrap dealer and with the proceeds but some 356 ingot - much easier to cast and if you give it a t5 heat treat like I do it will machine very nicely indeed. You should really watch the ramming as it is an important step - assuming of course that you can find someone who does it right (I do of course 😊) This channel does it pretty well too d. lazlo Pouring you should always watch as it is what makes or breaks a good casting I do it right but I am about the only person who does - the ladle (crucible) must be low, the metal must move as closely to horizontally as possible into the mould. You are right though to want to see the casting running system and all . Its nice to see the top of the casting too as that's where the shrinkage will likely be apparent -hence the on the block of ice people rarely show the top😊.... Martin
@@olfoundryman8418 Maybe your Mum and my Mum passed each other on the street one day. At least your Mum was smart enough to leave Winnipeg. Yes that's where I'm from. Lived here all my life. About the 6063 articles. I thought they were pretty odd. My thought was that it might work for decorative castings. Like plaques that some people make. But I have no interest in making plaques. I might do an experiment using the same pattern and do pours with different alloys. While I don't know the alloy, I do have automotive aluminum castings that I have acquired. All labeled as to what they came from. Wheel rim, intake manifold, water pump, etc. As far as watching the ramming and pouring stages. I have carefully watched you videos, many times over. Sadly there are not a lot of other channels that are worthy of repeat viewings. I saw one video this week where the guy took his copper ingot, previously cast from copper pennies, and recast it to a copper sledge hammer head. I have to say that his video productions skills is top notch. Oh, yeah, back to the casting. He cut up the ingot into pieces to melt and it was interesting to see all the porosity revealed. It was worth it watching just for that. You don't know what is inside until you look.
Hans, I gave up using recycled material 50 years ago because it caused me way more trouble than it was worth in any cost savings. What was the point I realized in spending all that time - making moulds, melting metal, pouring castings, breaking out and then reprocessing sand to wind up with way too many rejects. I took all of my scrap metal down to a dealer and with the pittance he gave me for it plus I purchased some decent certified ingot - 90% of my problems just went away. So I usually strongly advise others to do likewise. Go visit a local (small) foundry and see if for cash money they will sell you an ingot or two of (US) 356 alloy. However if you're determined to go down the recycling route I suggest that you only use only alloy wheels as these are usually the 356 alloy but do note that not all are - BMW wheels for example are not! I may one day do a video on materials to use but it's a big complicated subject. Note that you are unlikely to get as good a result with recycled materials as I got in this video - remember "garbage in garbage out".... Martin
Mister, Its not only the others that made those mistakes - I made many of them myself in my very early days. So I guess I am really trying to pass on avoiding mistakes I have made by using others as examples.... Martin
Wayne, Yes its been too long. The moulding bench is still a way off and sadly maybe a never as the pain level on standing is about a 9 out of 10. there is though a possibility (I see about this tomorrow) that I may get that down to a 5 or even a 2 in which case the bench will be back on... Martin
I am both amazed and very grateful as to how many of my subscribers and commenters are still around after what is an obscene wait of 2 years. Thank you all... Martin
Let's just say you have a cast-iron guarantee of our loyalty haha.
Glad to see you again and hope your doing well. You are one of the best.
im so glad to see you take on the you tube casting scene with some sound advice. its bean bugging me for so long, but i dont feel myself the authority to say to much.
Thanks for taking the time to make more videos. I have watched all your content and have learned much from your uploads. Many projects have been made thanks to the knowledge you have shared.
Just found your channel. Top notch! Watched 3 videos thus far and many of the questions I had are answered. Thank you for teaching!
Good to see you uploading again Martin. I like this type of overall guide / masterclass, so I can see these tips being implemented on individual jobs.
ViSc, Yep, its good to be back. I hope to do further videos in this line although I might ease up on the error pointing out and concentrate on the right way a bit more 😊.... Martin
@@olfoundryman8418 Martin, perhaps show a couple of mistakes others made before showing the correct way would work?
@@olfoundryman8418 hello, I'm new to your channel, I would like to know what product you make to make the sand wet, thank you.
@@olfoundryman8418 hello, that it produces that you mixed with the sand so that it becomes wet, thank you.
Delighted to see you're back and able to make videos again. Really appreciate the time you take to share your knowledge with us. Missed you during the past year or so. Hope your health is improving!
Eric, Yes, its nice to put a video out again. I am limited though to the sort of video that does not require much physical effort as so far health remains the same 😥. Some chance for improvement in the near future - maybe possibly perhaps hopefully... Martyin
What about taking on an informal helper. I bet there would be loads of people who would jump at the chance.
@@johnkelly7264 Yes, this has been suggested before and I have had discussions with one or two people but nothing ever seems to quite come of it. I am amenable to the idea but there are difficulties - it is much easier to show someone how to do something that it is just to tell them. There are things like getting the sand ready the day before helper(s) turn up and currently I am not able to do this as it is physically demanding. At the moment I doubt I could last for the 3 plus hours that a typical moulding session takes without at least an hours rest. But if anyone out there is serious about wanting to be a helper and lives close enough to Croydon Melbourne Australia then I would love to hear from you.... Martin
Keep posting Martin, sharing your hard earned experience is a gift to turd polishers everywhere.
Some of us even take your advice!
Flinstone. I will try to keep the posts coming. To be honest the turd polishers of this world are not my target audience for I fear they are not much interested in what I have to say. Its more those trying to do a good job and often frustrated by the difficulties and foibles of the process. But all are welcome to use what I say.... Martin
Thanks, I'm guilty to many of the mistakes you go through. Now I will do much better next time. 👍
Thomas, I used to be guilty of at least some of them too but the first step to getting better is to admit any mistakes clearly you are past this stage - well done..... Martin
I'm happy to see you posting again, thanks for sharing the benefit of your experience. And that is indeed a lovely looking throttle body casting :)
D. Jeff, It is good to be posting and I have to admit that it is one of the better castings I have done - that particular style of throttle body finished well.... Martin
I am so pleased to see you up and posting again. I've missed your wisdom.
Jim, Yes, its good to be at it again even if in only a limited way. Must admit I have never really thought of myself as wise just as a person who has been doing this for a while - a long while.... Martin
So good to see you upload!
I find it funny that I recognise almost every source for these mistake images, however I am proud to say I no longer watch any of their channels.
Why not watch them !? After this video of Martin, you will know where they are wrong. But that doesn't mean they don't show useful things. I also recognized many of the sources ...
I am glad that Martin is here again and gives us new knowledge!
Lancer, Evgeni, I watch them -well some of them - from time to time, sometimes just for comedy relief 😊 but also to see if they are improving and I am pleased to say that some of them at least are.... Martin
YOU'RE BACK!!! We so missed you and your brilliant videos. Thank you so much! Please sir, can we have some more videos? I hope you and yours are safe and well.
John, Working on more videos but they will take a little time.... Martin
You’re right. This is old technology. With enough learning, practice, casting can be nearly perfect. I want to start casting this year.
Peter, Go for it but be prepared for a bit of a learning curve..... Martin
I found this video extremely useful. While I generally seek out "what to do", I find "what not to do" perhaps more useful!
I'm quite glad that you're still around, as well.
elitearbor, Thank you for saying so. I do plan some more videos of the "what to do" kind. I am a bit uncomfortable with the "what not to do" type as it gets very close to denigrating other foundry video makers so another one of that type while possible is as fair way off - it takes some time to collect examples too, even though there are lots out there 😱 Putting them into a watchable video is a long winded process too, that video took about 3 months to do... Martin
Welcome back. I'm soo glad you posted. Haven't watched it yet. You are are reading my mind as I'm just putting the setup together for my first try.
Chuck, Well, you know what mistakes not to make on your first try 😊... Martin
I’m just going to thank you for your contributions to the you tube community. For very one already committed as to what I was going to say!
Brian, I appreciate your comment - the contributions are my pleasure... Martin
Loved it and learned a bit in the making, thank you. I've missed your videos. Can't wait till you explain more on the points you've mentioned. Oh and yes, what a beautiful casting example of surface finish, that's gorgeous.
Cobrin, Well I am back and hopefully I will be able to amplify some of the points in the video and mention a few more too - there are a lot more although many are quite subtle.... Martin
You’ve got to appreciate a straight talking Australia 👍.
Lessons learned and the proof of your skills and experience is evident in that stunning throttle body.
I hope you filmed them casting of that component 🤞🏼
North, Yep, a spade is a spade and all that.
I did film the casting of that throttle body. There is a two part series called "Casting the SR20 throttle body part 1"
th-cam.com/video/NXtTfJ-FG70/w-d-xo.html
And "Casting the SR20 throttle body part 2"
th-cam.com/video/r4P8kctZOkI/w-d-xo.html
.... Martin
Nobody ever learned to play the violin with a teacher who only pointed out everything he was doing right. This was a brilliant video, thanks.
Rod, I could not agree more - thanks for the comment.... Martin
I feel like I've been in the headmaster's office. I expected to see myself pop up as an example of every mistake discussed! Thanks for helping to stop the folly of us muggles Martin.
Flower, From Muggles to Wizards takes time and practice, many many years in my case just to get this far along. there is always further to go! I guess I am just trying to shorten the journey for others.... Martin
PS You never know maybe you will appear in episode 2 😊
Welcome back Martin, here's hoping you and your family and friends are all doing good, and that we'll get many more videos from you for many more years. You're such a treasure! Greetings from France.
Soda, Greetings from the great wide brown land down under. Its good to be back - family is well and thank you for asking, but me - eh - not so much, a lot of back pain on standing, makes it damn hard to do anything. A number of videos planed but its just the suffering through the doing of them. Not so bad if like this one it can be done almost all sitting down but to stand at the moulding bench is a bit of a stretch. Possibly another attempt at pain mitigation surgery in the near future - last two attempts have failed and I do not wish to resort to opiates... Martin
Your favourite TH-camrs are like old friends.
You miss them when their not there.
You worry about them.
You hope they are doing OK.
But when they pop back into your life, it brings a smile to your face and it brings you joy.
And you certainly are one of my (and many others) favourite.
Not just because of the content you create and the knowledge you share but because you care enough to share it with your TH-cam family.
I may never use any of the information you have provided but I have thoroughly enjoyed all your videos because I love watching a master at work.
Stay well old mate (or at least as well as you can).
Jack, "Old friends" yes, that is about right. If I have made even one of your days a little happier then I am happy. Doing my best to stay as well as I am (which is not very) but old age is making it damn difficult... Martin
I really like the way you share your experience in the foundry explaining the reasons.
Roger, My pleasure.... Martin
Let me start by saying… please never leave us again! Glad to see you back sir, and I’d love to see you make some new castings! I miss your videos! Oh man, I loved this video, you had me rolling, your commentary is the best!!! I feel honored for having some of my mistake clips make your video! I could go on and on for days, while I’m no casting master like you(I just do it for fun and hobby a few hours a week(so I’ll never be to your level)) you are an inspiration and a true master! I’d love to come spend a week with you and just watch you in action if I could. You’re the best Martin!
PS- if you ever feel like doing a voice over for one of my videos and really roast me down to size, and send it to me, I’d get the biggest kick out of that.
Growing, Thank you for your rather nice comment. I had great trepidation in releasing this video as I feared for a lot of bad reaction, wonderfully I have to report that I have not had even one bad comment🤗. I did try to make the - ahem - borrowed clips as anonymous as possible but it was obvious that where they came from would not be that hard to determine. However, for four reasons I will demur on your voice over idea.
1: Ripping apart just one persons single video is just a bit too personal.
2: I have in the past provided information like that (sort of) privately to people just for their own private use, but they have used it to release "50 ways to leave your bad castings behind" videos as though they were an expert even though they have made at most a handful of very ordinary castings. In doing this they have released information before I had a chance too, thus robbing me of many video ideas. This has happened to me several times and several times bitten most definitely very shy. This is very mean of me I know but I too have a right to a little YT success
3. Because of 2 any critic would have to be a released video on my part i.e. public. To "attack" another youtuber so publicly and completely is not my way. To cause them embarrassment in front of other youtubers (most of whom are equally as bad I might add) is not something I wish to do
4. I looked at two of your videos - your latest melting down aluminium wire and one where you melt down a large ingot of (the wrong) zinc alloy
to make a hideously bad mould rammer design. At a quick look in the first of these there was 15 mistakes in the second about 30! Many were only small mistakes but some were big....... Martin
@@olfoundryman8418 Thank you for the reply. I totally understand you not wanting to do a funny roasting voice over, although I still think it’s a great idea, you could totally preface the video that I asked you to do it and post it on your channel(And I only mentioned send it to me, not for me to sell you out and post it myself like you said others have burned you in the past, but I was meaning for my own private enjoyment to cherish) but I’d share the hell out of it if you ever did. From your #2 last sentence, Its not mean of you, I’m surprised more people aren’t subscribed and watch your videos, and I’ve never given you a shout out yet because, as you can tell, my techniques that I’ve tried to teach myself and “learn by doing” would be a discredit to you 🙂
-although I should ACTUALLY try some casting tips from you(to better myself) and add a title that I learned it from you and tell people to check out your channel. Maybe I’ll try that this weekend 🤔
I’m a comedian at heart, so the idea makes me giddy, and I’m old school so nothing hurts my feelings like that. I even had to re-read #4 in your voice(which is the best, not joking about that) and I can picture an ‘Ozzy man reviews’ style video of the zinc sand rammer video.
“Aaannnndddd we start right off the bat with the worst design of a sand rammer you can possibly choose. He’d have a better bit of luck with it if he just shoved it up his tailpipe. Oh wonderful, he’s chosen a zinc alloy, albeit the wrong zinc, but by the looks of his “shop” if you want to call it that, he obviously can’t afford a quality zinc alloy. I mean come on, is that plywood on top of a shelving rack??” 😂
Sorry, I’m a little kid at heart and think that kind of stuff is funny. Anyway, if you ever change your mind send me an email thegrowingstack@gmail.com, aside from all of this I’d love to be able to email you personally and call you a friend. Sorry for the novel, you’re the best Martin, have a great weekend!
Thanks Martin. Good to see you back.
Mark, Good to be back.... Martin
I really appreciate your honest and candid manner to WHS and your willingness to educate. Cheers mate. Oh and thanks to "Vogman" re Lost foam casting who put me on to your channel.
glen, Thanks for your comment. I hate to see foundry "done wrong" so hence this rather feeble effort to point out some of the traps people fall into. My thanks to VOG for the referral. We used to be in regular contact but sadly out relationship sort of drifted apart.... Martin
i am so sorry to hear of the drift. you both offer so much valuable content. I am learning for a disability client of mine so I can teach her and myself from the master's such as yourself. We truly appreciate your guidance. Thank you.
Good to see you putting a video up again. Following your advice from a couple of years ago, my castings have improved a lot, but I sill have a long way to go. I am still making mistakes that would be very difficult to identify without videos like this to help. Thanks again.
Ian, Good to hear that your work is improving. I am happy to think that my videos may have helped with that. We all sometimes need help identifying what went wrong. I have often noticed in some videos that both the videoer and the commentators get it badly wrong when identifying the cause and cure of a problem. At times I get stumped too, and have to begin a literature and peer search for answers.. Martin
Glorious to see you back!! Made my day. :-)
Andy, Gee some people are easy to please 😊. I hope the rest of your day was as good or better..... Martin
Those 4 little pulleys on the enormous sprue were mine, cheers chap, only just discovered your channel it's very useful and I'm honored to be an example of what not to do.
Turbo, Do you mean the 4 little wheels at 2.42? While you may have done something similar these ones were not yours. I won't let on who did them other than to say he is a fellow countryman of yours who has been on YT for quite some time. I see that you are a material engineer - well I guess that sort of makes two of us - I am a metallurgist. You should enjoy those books of John Campbell's that I mentioned in the video. The info in them blows the cobwebs right off the 6000 year old technology still in use by way too many foundries..... Martin
@@olfoundryman8418 Martin you are of course correct, my similar pulleys, sand and excessive flashing stuck with me.
I'll certainly keep my eyes peeled for those titles and continue my education with your videos, this one alone answered many questions around my own failures in both greensand and permanent.
Professionally I'm a maintenance engineer but at home I'm a life long student of material science, it gives me a lot more leeway with f'ups.
James.
Great to see you back Martin!
I've been an occasional caster for over a decade. When I started out I was probably making all of the mistakes you outline here, over the last 5 years or so I've been incorporating the methods you show on TH-cam into my work, and I can definitely see the improvement. I still have some way to go and I'm sure if you were to see my videos you could point out a number of errors (some admittedly due to my own laziness).
Your videos are my (and I'm sure many others) favourite source of casting information, I know you've been suffering with health problems and it may be a while before we see you back at the moulding bench, but more videos in this type of format would be equally welcome.
Cheers from sunny England!
Andys, Greetings back from a cold powerless Melbourne where even if there was power you could not afford it. I will checkout some more of your videos (have seen some - was sent to your channel by smallcnclathes) who knows what I might find. He He😊. If I have been of help to you I am well pleased.
Mistakes are of course part of the process... Martin
Welcome back Martin!
Wikus, Good to be back... Martin
Bloody beautiful work Martin. I wish we could get you delivering lessons to us nuff nuffs. Cheers 🍻 Aaron
Aaron, I can not guarantee that I can get you doing work like that first up but we must put our heads together to see what we can come up with re lessons - If you can do all the physical stuff while I sit on a chair and bark orders we might be able to get something done. Start thinking about something that you would like to cast as a first up.... Martin
I've actually started implementing some of the mold designs (feeders, risers, etc) you show into rubber molds meant for resin casting, and it's resulted in better castings all-around. It takes a little more time to make, but considering the time I'd otherwise spend grinding resin, it's worth it.
Thomas, Interesting. Is it because of less air entrainment do you think? I looked but you do not seem to have any videos up about this process - a pity - I would like to have seen some. Its the same with metal much better to cast it right and therefore not have to grind it lots... Martin
@@olfoundryman8418 I think it's mainly because the resin doesn't suck in as much air and mix it in due to turbulence.
@@thomasbecker9676 Exactly the same as with metal - not surprising I guess as both are fluids.....Martin
When a guy makes a product that fine, there likely was a bit of a learning curve to get there! Thanks for always sharing the knowledge.
James, Yes, indeed there was a bit of a learning curve - initially very steep and a slow still continuing grind from then on. Part of my idea with a video like this is to nudge people a little further along the curve and thus save them some time - I mean, why should everyone have to reinvent the wheel.... Martin
Good to see you back again Martin. It has been a confusing two years for everyone, so it is time to start moving forward again.
Mark from Melbourne Australia
Mark, It may have been confusing for you but it was bloody frustrating for me. It's still difficult and how much I can "move" is debatable... Martin
this video is the gold standard, when it comes to casting. really well done!
Christoph, Thank you.... Martin
Thank you Martin ,
Just to let people know that Martins castings are of high quality. A man with many years of Experience,
I have use his castings in the past , very clean and great Machinability,,
Martin you have Been. a great Mentor and a Great Friend to many people,
Just want to say
Thank You..
Oliver, Thank you for your most kind comment. I am happy that you got the castings that you wanted... Martin
I second that, as a customer I have used thousands of Martin’s casting both sand and gravity diecast. Quality was never an issue and always machinable on my small cnc lathes, which says a lot.
Oliver, Are you the Oliver from "Brass from the past". If so where have you been all these years?... Martin
Good to see you again. Hope you're over your health problems. Thanks for sharing 👍
Craig, Sharing is my pleasure. Sadly the health problems are still much the same hence this was an "inactive" video. It may be a while before I can return to the moulding bench.... Martin
I have never made a casting and I may never, but I absolutely love your channel because of the detail. I sure have missed you thanks for coming back. Knowledge is power.
Paul, Come on get out there and make a casting 😊 its a skill of great use and a lot of fun (sometimes😊) You have the knowledge - use it. But use it or not thanks for watching.... Martin
@@olfoundryman8418 You're right. When I purchased my TIG welder now I use it way more than I thought. I'll put casting on my short list. Thank you for your time and putting your information into our hands.
Greatly appreciated, Sir! Especially your no sugar coated delivery, it's really clear, no pretentious BS.
And it's really open my mind.
Surya, Mind opening was my aim. Thank you for your comment.....Martin
I've nearly finished reading all of John's books and I've got to agree with you, they are a pretty hard slog. However, as you clearly demonstrated with that gorgeous casting, the proof of John's techniques are in the end product.
Dean, All of them - WOW that's quite a effort well done. My mathematics is not really up to the task. I find myself reading and rereading them at every opportunity - doctors waiting rooms etc anywhere 15 or so minutes is available. I often refer to them when problems arise or a new job comes up - often now on behalf of someone else of course...Martin
jam-packet full of expertise =) Thank you for sharing this bit of your wealth of knowledge on the matter! You did sound a bit angry at times... I remember a very serene image that I got of you from your older casting videos. Don't let the silliness of dumb young blokes get to your heart! I always love to see your videos, because there isn't a single one that didn't teach me new knowledge :)
I think Luke that is passion rather than anger. Martin is quite passionate about foundry work and hates to see folks doing it badly when with a little effort, huge improvements can be made.
@@smallcnclathes Yes, I'm sure it is. I don't think I meant actual anger, more like his professional pride (fully deserved) causing some vicarious shame or appalled disbelief that they would broadcast such mistakes out on the internet as proper practice. I've been following him for years now, 6 or 7 I believe, and the videos he puts up are not only always teaching me something, but watching an experienced craftsman at work has always been oddly satisfying for me.
Luke, Basically smallcnc is right, its passion and love for the "genteel" arts of foundry. I do however admit to occasional fits of a cross between amusement, amazement, and yes anger at what I see some do to those arts. Its the people who are have no interest in doing it right and seem only interested in how many views and subs they get that do try my patience. People, who like yourself, learn something with each video are my salvation... Martin
@@olfoundryman8418 And you are ours... Seeing your videos reminds me how I want to excel at a trade too. My situation makes it very easy to slip into a passive state, and watching videos like yours actually stimulates the creative part of me. So aside from the knowledge base that teaches me new techniques or solutions, these videos are also a kick in the butt to get off my behind and get my hands dirty =))
Martin,
Glad to see you back.
I'm glad you are repeating information regarding Campbell books. Some of us are listening to what you have been saying.
I followed your advice, and bought his complete textbook. There is so much information in there, for everyone. The section on sprue gate and metal velocity during a pour.
I hope you can find something that can help with the back pain, we are rooting for you and your pain-free future.
Mr Eric, You bought the big book - you are a glutton for punishment! Even as an experienced foundryman and a qualified Metallurgist there are parts of it that I struggle with but it is a great resource. I go to see a surgeon about the possibility of pain mitigation surgery (tries one and two failed) in a couple of days - maybe I will get lucky this time. Pain free is most unlikely but a good reduction is a possibility...Martin
It's great to have you back, pure gold. Thanks mate
Lyall, I hope that I can keep the gold up... Martin
Thanks mate…some very useful info there. Down the track I want to give casting a go, so any info given is greatly appreciated 👍👍👍👍
Garry, Forget that "down the track" just get out there and do it. If I have helped nudge you in that direction and provided some useful info then I am well pleased... Martin
You my friend have helped me out immensely and I thank you for your years of hard work and knowledge that you have acquired to be able to do so.thank you again.
Daniel, Glad to have been of help... Martin
Welcome back.
Best channel for casting ever...
nume, Nice to be back - thank you.... Martin
Welcome back sir, it is good to see you again.
Christian, Nice to be seen again..... Martin
Hello Martin, I am so glad to see you here again after such a long time. I hope that you are well. Your advice is always welcome. Thanks to you I have been able to make some parts for my old EBRO tractor (Fordson Super Major design made in Spain) Greetings from Galicia, Spain
Pedro, Greetings back to you from Melbourne Australia. I am glad that my advice is welcome and that it has proved useful with the tractor, And thank you for saying so...Martin
Great to see you are back, you have the viewer's respect and loyalty for the information and the way it is presented. As I am sure everyone agrees great job, a true treasure trove of knowledge.
Brad, Good to be back and thank you for your nice comment. Martin
Oh this video was an eye opener!!! Thank you for taking the time to explain what doesn't work well when casting. Well done!
Metal, Sadly to many copy the mistake makers and thus not only perpetuate the mistakes themselves but spread them on to still others who mistakenly think that those they are copying have it right. - I just had to do something to all least correct a few of the worst of the errors.... Martin
thank you so Much!!! finally another person pointing out the terrible practices that are being made popular by the TH-cam algorithm. I don't feel alone anymore
Henry, You are not really alone! There are some good foundrymen out there. they are just quite about it. Take Kelly Coffield the lost foam genius or d laszlo the steadiest pair of hands in the moulding game, watch him with composite petrobond/greensand work - just brilliant. Or Luckygen1001 a 40 plus year cast iron veteran, like me he speaks his truth.
But yes, YT has a lot to answer for when it comes to spreading misinformation, nothing that they can do about it though. Its up to the viewer to sort the chalk from the cheese, assuming he knows the difference of course and sadly, he often does not.... Martin
wow!!! super awesome!! I am gearing up to start doing some casting of parts for my soon to come 1928 Morgan Special build.
John, Thanks for your comment. Good luck with the Morgan older car restoration always seems to need castings.... Martin
@@olfoundryman8418 Thank you Martin. You are my inspiration. I would like to get into more casting on a full time basis.
thank you soooooo much for sharing your knowledge! glad to see you back.
Fabrication, Good to be back and sharing the knowledge is my pleasure.... Martin
Thank you for these absolute gems of knowledge! It's good to see someone on youtube who approaches casting the good way.- Gábor (a guy who is doing academic research on oxide films)
Gabor, Thank you for your comment. Yes, I try to follow the great Guru John Campbell although I have many questions some of which relate to how one can and how far one should adapt his work to the small scale moulds that we hobbyists work with. I wish I was young enough and in the right position to do the sort of research work that you are involved in. The foundry industry needs all the help it can get from people like yourself. Have you published any of your work - I am always keen to learn more and read all I can find..... Martin
Super helpful video Martin. I didn't make your hall of shame this time, which was a good thing. I am trying to implememnt your lessons. Keep this stuff coming.
Rotary, Hmm, maybe I should check out your channel to see if I can find some suitable slip up to highlight 😊 Ah yes, that Beatles fail looks to have the odd - ahem - hiccup. That spherical bottom pouring basin for example - the shape just makes the metal ricochet out if you try to keep it appropriately full during a pour - hardly mattered in this case with the blocked sprue and all (happens to all of us). Still we learn much more from our less successful efforts than from our great successes. Hang in there.... Martin
This is really incredible. I have an old lathe and they dont make the parts for it anymore. Ive been looking into making my own for this reason
thedude, You have hit upon one of the reasons for undertaking foundry as a hobby - the ability to make bits that are otherwise unobtainable or to expensive. It can be a very rewarding thing......Martin
Thanks for making this video. Love how versitile the modular sides are.
MrEH, I think that the only limit to the versatility is ones imagination and I am sure others could expand on my simple examples.... Martin
Great to see another video from you again. Thank you for taking the time to pass on your knowledge from all the years of your experience in getting great results! I look forward to this series of videos.
Macwhirter, I do have more planned but I don't know about a series - we will see.... Martin
Great to see you Posting again, hope to see more soon.
Warped, Hopefully more coming out soon next month or two.... Martin
It's wonderful to see you back. Thank you so much for sharing your knowledge with all of us.
Tyler, Good to be back. Sharing is why I am here... Martin
Martin, always a pleasure to hear your well experienced and solid advice. There are so many atrocious casting video's out there and beginners follow using the same atrocious failing techniques. Your advice is spot on, read and understand the materials you are working with and above all observe and analyse not only what goes wrong with your castings but what went right and develop your rules accordingly. Had a chat with Dave at Outlaw Castings at Lake Goldsmith, he is doing some fine work in his set-up, great to see someone who knows what he is doing passing on his experience in his casting demonstrations.
Cam
Cam, It was actually a few of those bad videos that got me on to YT, I felt the compulsion to try and counteract the bad info out there. Sadly my success rate had not been all that I might wish for but clearly I am reaching some people including I think those that actually want to improve rather than just get more views... Martin
Well said Martin. You're spot on and advice welcome. As you would know. You can lead a horse to water.
Keith, Horses water yes, indeed. The problem is that some "horses" prefer to just stick in the past or are content with views and do not care about good castings.... Martin
Martin, Great to see you posting a new video. I like the rest of your followers/subscribers look forward to future videos whenever you are able to post them. From the shores of the Chesapeake Bay in Maryland, USA thank you for sharing your knowledge and wisdom
gull, Yes, it was nice to put a new video out. Md you say - hey, we might be related😊 my earliest know male line ancestor arrived in MD 1677 as an 8 year old indentured servant He prospered, taking land right on the Md Pa border, at that time disputed territory. Greetings back from Melbourne Australia..... Martin
i think perhaps you undervalue your skills and knowledge, to make a casting like that takes all the lifetime of experience you've had.
stunning work.
I think the difference is in the 10-15 attempts of the first timer (like me) and Martin's one shot to perfect.
@@lancer2204 and that comes from the right attitude and a lifetime of experience.
Axe man, Lancer, "one shot to be perfect" - hmm I wish it were so. Every new job has its challenges and I often come up with two or three scenarios to cast the part, try them all and then pick/modify the most successful. Those throttle bodies were perfected over many designs and many years - you just have to keep plugging away.... Martin
The Master has returned! And in full form! TH-cam, prepared to get schooled.
Really warms my heart to see you are back Martin. Hope your health is treating you a bit better these days. I can not wait for more of your mentoring. All the best, Jaime from the Blue Mountains.
Jamie, Blue Mountains - nice spot. Health no better but I can manage videos like this one where not so much physical effort and little standing up is required. Hopefully I have more on the way.... Martin
2 years of bated breath wondering if you would ever share more if your casting wisdom.
Thank You for returning to further our knowledge of this industry.
A-K, Lots to share but health issues make it hard and slow... Martin
@@olfoundryman8418 Hoping you may more years to go. We're rooting for you.
Very interesting video. Nothing speaks like experience
Skip, Experience is not the only teacher out there but it sure does a good job of it. Just about all of the errors mentioned were down solely to inexperience... Martin
Great to see you back Martin. Looking forward to casting Box completion.
David, Yes, its good to be back and I am trying to finish the moulding box series but back pain after just a few minutes standing is making it very difficult..... martin
@@olfoundryman8418 I've been having serious back pains myself for the last few years and I now try avoid eating tomatoes and eat more coleslaw (the apple-cider recipe) or Sauerkraut.
@@DavidMullins1 Thanks for the thought but sadly my back is well beyond any easy means of pain relief. I saw a back surgeon today and he is going to implant a nerve stimulation device that MIGHT (50:50 chance) reduce the pain level to where maybe I can get to do what I want regarding making more videos etc. Anything to avoid strong (addictive 😱) pain meds... Martin
Big thank you. I think most of us started out with "how to" on youtube. We really need "how not to" every now and then to learn to correct our mistakes. Please keep teaching. We will learn.
All, I do plan more and they will be both "how to" and "how not to"... Martin
G’day Martin. It’s Aaron, this is my other channel. Your video was that good I had to come over on this channel to like and comment also. Mate you had me in stitches through that video with some of those comments. I’m rolling on the floor laughing. Hope you’re well mate look after yourself all the best Aaron
Aaron, Yeah, sometimes I have no other reaction than laughter and sometimes that's all you can do in reply to some of the stuff I have seen If I did not laugh I would cry..... Martin
Thank you Sir, the best video I've seen about casting, and the quality of the result piece is amazing
Rick, Thank you and yes I was quite proud of that casting.... Martin
Holy cow I didn't notice that you were uploading again until now! Now I have a queue of videos to watch! Glad to see you back Martin!
Net, Well, I am sort of uploading! There is a limit to what I can do but there are a few more on the way... Martin
Oh this entire video is beautiful. I miss the lecture type format of old youtube videos.
I'm taking on the gingery machine tools challenge as my first casting projects. I wanted to dive in headfirst and learn from other people's experience. Im 100 percent not good at it at all, but im learning through watching videos like yours.
Doble, Thanks very much for your wonder full comment - I could take comments like that all day! I don't meant to be a bit of a downer but I am not much impressed with the gingery machine tools. The problem is that aluminum has very little ability to damp out vibrations. There is a good reason why cast iron is used for machine tools and that is its excellent vibration damping ability. With aluminium your will get a lot of trouble with chatter and likely have to take small slow cuts. Still, I guess its a good learning exercise..... Martin
Great to see you back Martin!! I missed your uploads and wise words!!
JB, Well, guess I am sort of back. Restricted in the main to videos I can do sitting down, but I have few planned... Martin
May God give you all the best Mr. Martin. I have a lot of difficulties since I want to change the method of my cake mould aluminium production, from sand to permanent mould. God direct me to your channel youtube, big thanks. Sometimes I think I want to learn directly to you. May God give you All The Best, ameen. Big thanks Mr. Martin
mieko, Thank you for your comment. If I have been of some help to you in your casting work I am well pleased..... Martin
So glad to tap into your wisdom yet again Martin. Was getting worried as so long between posts, now this is superb info which I will take on board. Many thanks
Allan, Yes, it was a long time - too long. I do have more planned but at the moment I have to find topics that I can cover without getting too hands on at the moulding bench as that is currently beyond me. There was a fair bit more I could have included but examples available were a bit to obvious as to there originator. Also of course there was a bit of a limit on video length - I did no want to go on for hours 😊.... Martin
@@olfoundryman8418 Your wisdom is always welcome
You are a most welcome return to my TH-cam diet Martin, welcome back. I am 25 years into retirement and have many yet unfulfilled aspirations, one being to produce some useful castings. I hope that you have best ergonomic setup at the computer because many hours editing videos can be hard on the spine. Hope the treatment is successful and that you successfully navigate this Covid nightmare that our beloved city has become. Stay warm.
Penyll, It is good to be back. 25 years into retirement - wow! You must be even older than me -I hope that you are in better condition 😊. While Covid has been quite an issue I think it the least of our cities problems - massive gov debt, politicians treating us like mushrooms, suburban infill, our children being taught absolute self denigrating rubbish. explosion of Woke, anti-car practices, treasonous politicians removing and/or denigrating our flag. - Stay warm - well , yes if only I could afford the gas or electricity - assuming of course that it was available. I could go on but had better get of my soap box before I stroke out 😊... Martin
Great to see you back and we look forward to more...
William, Nice to be back and working on more.... Martin
Glad to be joining the club, thanks for everything you’ve shared so far, I’ll be sure to go through your uploads and learn as much as possible
Jamie, Glad to have you aboard.... Martin
So happy to see you back on TH-cam. I've missed your insights. Wishing you all the best. Cheers 😀
Earthy0, Thank you - good to be back... Martin
thank you so much for passing on your hard won knowledge through this channel.
q1, I am happy to be able to share what I have learnt - I hope that you find it useful.... Martin
So good to see you online again, Sir!
Thank you, so much, for sharing your methods and processes.
Karl, It is good to be back online again, more to share soon I hope... Martin
@@olfoundryman8418 I just know that my small iron/bronze foundry efforts have been advanced significantly thanks to your sharing. It is very much appreciated.
Karl, That's what I like to hear.... Martin
Thank you for posting, that was the 101 of casting.good stuff this you tube with operators like you
Andy, Glad that you liked it... Martin
I came across one of your vids about a month ago and learned a lot. More than Inever learned from the professionals around me wben they're on the high horse. I don't cast but I was enthralled but your matter of factness. Its been on my mind for 30years tho.
I'm glad I waited and didn't become a turd polisher. There are toooooo many of those folks in the world.
Slinky, Yep, YT is full of turd polishers - their only interest is in making a video it doesn't matter what about as long as it's a video. IMHO a waste of space, time, and fuel that contributes nothing to the wider knowledge of foundry. 30 years? Time you got on with it 😊.... Martin
Thanks for your videos and tipps.
I'm preparing for my first mold and sucking up every information I can get 😁
hatta, I hope that some of the info "sucked up" will help you to get a good result early in your casting endeavors.....Martin
So happy to see another of your videos! Thank you so much for sharing your experience and investing the time to make these wonderfully informative videos. You are truly a master and my hobby has benefitted greatly. Thank you, thank you, thank you!!
David, If your work has benefited then I have achieved my aim and thanks (very gratefully received) is not necessary... Martin
Good to see you back Martin. Hope all is fine with you.
thinge27, It is good to be back but things really are no better with me, As it stands the moulding bench is out of reach - there is a chance though ... maybe.... Martin
Martin please keep them coming! You are an inspiration. I am just about to get my home made foundry online. I am attempting to cast a bellhousing for my little Lotus project. I hope to have some pictures to share soon :)
Charles, A bell housing is quite a big casting! Good luck with it and bravo for trying.... Martin
Hello Martin,
Many thanks for making this video and your straight talking... enjoyable viewing.
Take care.
Paul,,
Knackler's Ah well you know us Aussies - never ones to hold back 😊 Glad that you liked it.... Martin
G'day Martin, good to see you back, I'm looking forward to more. Cheers Peter
PGS, There are (hopefully) more on the way and I wil try not to be quite as long about it next time... Martin
I am extremely guilty of making many of the mistakes you point out here when I first started. However, after Perry recommended your channel to his viewers, and having gone through your videos, taking notes and video times for reference, and taking the time to order Professor Campbell’s books for reading and studying, I have learned quite a bit and am slowly gaining experience in my casting attempts.
I love that you really hit on the safety aspect of casting, particularly on one individual who thinks that relying on the Leidonfrost effect to keep him safe is acceptable.
I’d say my biggest improvement to be made is in making a proper sized pouring shank for crucible. It took me over a month to make a decent set of simple lifting tongs, so I am still working on getting a good pouring shank made.
Great to see you upload and call out the improper practices you see, while helping us newbies understand why these things can be dangerous or why they’re important to do right. While I’ll probably never make more than artsy pieces with less-than-favorable aluminum alloys, I think that having the opportunity to increase knowledge of foundry work, the science behind proper pouring practices and techniques, and good safety practices, even for just a backyard hobbyist, is critical for future generations who get in to this as a hobby.
Super, We all make mistakes particularly when starting out. What matters I think is that we learn as we go along and not make quite so many.
Personally, I have little faith in the Leidonfrost effect. The initial "hit" of a splash on the skin will break through any such effect - sure it may come into play in the few following seconds but the damage will be done, and as for radiant heat it offers no protection from that. And radiant heat has got my pants to smoke and burnt me through a layer of clothing - the man is an idiot.
The right tools are essential without them it is just not possible to do a decent pour.
Nothing wrong with "artsy" pieces and the experience making them will stand you in good stead if - with appropriate alloy changes - you ever need to make a true engineering casting... Martin
Really interesting and informative. Seeing all of those examples in one place at one time is invaluable.
Brian, The sad thing was that I could have put hours worth of such examples in. Many areas that I wanted to get into I just did not have time for. Stay tuned as in future videos I hope to expand things.... Martin
Whoop Whoop, Martin is back on YT, nice to see you put something out my friend.
There is always things to learn & no substitute for experience.
Andy, Whoop Whoop indeed! Hopefully I will have some more to follow and with luck they will not take the months to do that this one did - I just have to get through replying to all these comments first 😊 ... martin
So good to see you're back. Edit: I strive for your level of casting ability. I'm not there yet, but I am making improvements.
Amalgamous, Well I am sort of back! That level took a fair bit of practice but more than that it took a constantly questioning outlook - how can I do it better? (And quicker - I had to make a living after all). If you always look for improvements with an open mind (sadly a rare thing amongst foundrymen) you wil get there.... Martin
Good to here from you again Martin.
B Clare, Good to be heard.... Martin
Great to see another video from you again! This one was awesome.
Bruce, Thank you - glad that you liked it.... Martin
Excellent video, I always enjoy watching knowledgeable people discuss interesting topics
Heimo, Thank you for saying so... Martin
Good to see some more educational videos, building a small forge out of a keg and will be using your videos to get started on casting.
Danny, Aren't beer kegs wonderful things. I have one as a quench tank and another as a fuel tank, they sure make good furnace surrounds too.
Take it slow when you start, easy things to begin with and work up from there as your experience and confidence grows - there is a lot to get your head around at first. Good luck... Martin
I am always excited when I see that you have posted a new video. I'm glad that you still have more videos planned even though they will not include actual casting. While I have learned much from your casting videos, I welcome any new videos about the things you have learned about casting.
When I was in school we had "Shop" classes to teach hands on skills. I remember one term was metal working, that included sheet metal forming and aluminum casting. I ended up taking taking an electronic technology course in college and was fortunate to have worked for electronic manufacturing companies.
The first year was in the testing department of a large telecom factory. The next 12 years was at a tiny electronic shop where I we had our own line of alarm panels, and we also did some custom design and manufacturing for other small companies. I did design, purchasing, assembly, testing, customer support. I learned a lot there. I then moved to a small (but bigger) electronic manufacturer as the senior electronic designer. After 25 years there I finally retired last month.
I have always been interested in design and manufacturing processes. Working for small companies, I didn't get paid a lot, but I was involved in all aspects of product creation. I have a small workshop at home (lathe, mill, etc.) and had used it often in project development for work.
About fifteen years ago I made myself a small electric furnace to do some metal casting. I decided to start with zinc based metal due to the lower melting temperature and because I could get away with using welded steel pipe (thick walled) as the crucible. The first attempt was pretty spectacular, due to the sand being too wet. The second was a little better but still too wet.
The third attempt went pretty good. I had a 125mm injection molded timing gear as a pattern. I knew the draft on the part was insufficient, and the outside perimeter flange was too thin, but I just wanted to cast something. Because of the lack of draft I think I had a problem with one edge contacting the other half of the mold when I was reassembling it after removing the pattern. A little shifting of the sand. There was some shrinkage in the center. I plugged the drive shaft hole in my pattern and I did not provide a riser. There also was some shrinkage on the inside of the rim where I had my gate cut. It had a little rough finish, but I was surprised at the level of detail retained. There was a small circular paper label on the inside surface and it is clearly present in the cast part, along with the molded in raised part numbers.
Unfortunately that was the end of my experiments in casting until last year. I did a couple of items and incorporated many of the things I learned watching your videos. Still there were flaws but every flaw was explainable. And a learning experience.
With my approaching retirement I decided to purchase a few different size crucibles so that I can cast aluminum. Only the smallest size will fit into my existing electric furnace. (4"x4"x9" inside dimensions, made for my 3.5" o.d. steel pipe) I have made up simple, but proper, lift out tongs and a pouring shank for the new crucible. I hope to give them a try withing the next couple of weeks.
As I stated, my current small furnace is electric. I live in Canada in an area where half the year is cold to very cold. This is one of the reasons I prefer an electric furnace. In my basement I have a small welding chamber that I can use in the winter. It has piping and a fan to exhaust welding fumes, with a minimum of heat being pumped out the building. (with -20°C air replacing it) I still have enough insulating firebrick to make a bigger electric furnace but I am concerned that it will take too long to get the aluminum from melting temperature to pouring temperature.
Over the years I have been collecting aluminum at work. When we scrapped sheet 3003 aluminum for discontinued parts I would collect it. I also collected a lot of heatsinks, 6063 extrusions, from returned or scrapped production. I had assumed that I would sell off the aluminum and replace it with proper alloys for casting. A couple of months ago I was surprised when I came across some research papers where 6063 was used for casting tests.
Investigation of Mechanical Properties of Aluminium Cast Alloy (6063) By Varying Chemical Composition
www.irjet.net/archives/V5/i4/IRJET-V5I4689.pdf
Effect of casting mould on mechanical properties of 6063 Aluminum alloy
jestec.taylors.edu.my/Vol%207%20Issue%201%20February%2012/Vol_7_1_089_096_WASIU%20AJIBOLA%20AYOOLA.pdf
Modelling the Mechanical Attributes (Roughness, Strength, and Hardness) of Al-alloy A356 during Sand Casting (one compared alloy was 6063 aluminum)
www.ncbi.nlm.nih.gov/pmc/articles/PMC7040807/
Because of these I decided to give the 6063 I have a try before bringing it to a scrap yard.
When it comes to casting videos I like they never seem to include putting a hot ingot on a block of ice, or into a bucket of water in a plastic pail. What I want to see is a part being made. I don't care for metal muffins or pouring molten metal into water or ant hills. What I like to see is the pattern of the part. Why it was made the way it was, if there were any casting challenges. Cores for example. How it was gated and risers used. Ramming sand (unless special precautions need to be made) and pouring metal generally I skip. I like to see the cast part and the attached gating and risers. Anything that would explain why the pour went well, and why it didn't.
When I look at a part to be cast I think about solidification, where and the path, until solidification.
I appreciate the Oldfoundryman videos, and a few other channels that produce quality casting content. I hope that when I ever make my own videos that I would provide good informative content.
(sorry about the length)
Good comment Rudy
Rudy, I am guessing that you are from the "French" part of Canada - not that it matters of course. I know of the Canadian cold - not first hand but both my parents were Canadian, Mum from Winnipeg, Dad from Agassiz BC and both often spoke of the cold and how glad they were to be in a warmer climate 😊. But I would love to be able to visit Canada as it looks to be a truly picturesque place.
Re 6063 those articles seem to give a confusing idea of the hardness with readings from 30 Hb to 80 Hb. At 30 the material would be like chewing gum and thus unmachinable 80 would machine quite well. However 6063 does not have any significant eutectic in its structure and thus you will struggle to get a good sound casting with it - you will be making it hard on yourself by using it. My suggestion is that you sell the 6063 to a scrap dealer and with the proceeds but some 356 ingot - much easier to cast and if you give it a t5 heat treat like I do it will machine very nicely indeed.
You should really watch the ramming as it is an important step - assuming of course that you can find someone who does it right (I do of course 😊) This channel does it pretty well too d. lazlo Pouring you should always watch as it is what makes or breaks a good casting I do it right but I am about the only person who does - the ladle (crucible) must be low, the metal must move as closely to horizontally as possible into the mould. You are right though to want to see the casting running system and all . Its nice to see the top of the casting too as that's where the shrinkage will likely be apparent -hence the on the block of ice people rarely show the top😊.... Martin
@@olfoundryman8418 Maybe your Mum and my Mum passed each other on the street one day. At least your Mum was smart enough to leave Winnipeg. Yes that's where I'm from. Lived here all my life.
About the 6063 articles. I thought they were pretty odd. My thought was that it might work for decorative castings. Like plaques that some people make. But I have no interest in making plaques. I might do an experiment using the same pattern and do pours with different alloys. While I don't know the alloy, I do have automotive aluminum castings that I have acquired. All labeled as to what they came from. Wheel rim, intake manifold, water pump, etc.
As far as watching the ramming and pouring stages. I have carefully watched you videos, many times over. Sadly there are not a lot of other channels that are worthy of repeat viewings.
I saw one video this week where the guy took his copper ingot, previously cast from copper pennies, and recast it to a copper sledge hammer head. I have to say that his video productions skills is top notch. Oh, yeah, back to the casting. He cut up the ingot into pieces to melt and it was interesting to see all the porosity revealed. It was worth it watching just for that. You don't know what is inside until you look.
Just came along your video... like it very much.
Please make a video on how to improve your home cast with recirculating aluminum.
Hans, I gave up using recycled material 50 years ago because it caused me way more trouble than it was worth in any cost savings. What was the point I realized in spending all that time - making moulds, melting metal, pouring castings, breaking out and then reprocessing sand to wind up with way too many rejects. I took all of my scrap metal down to a dealer and with the pittance he gave me for it plus I purchased some decent certified ingot - 90% of my problems just went away. So I usually strongly advise others to do likewise. Go visit a local (small) foundry and see if for cash money they will sell you an ingot or two of (US) 356 alloy. However if you're determined to go down the recycling route I suggest that you only use only alloy wheels as these are usually the 356 alloy but do note that not all are - BMW wheels for example are not! I may one day do a video on materials to use but it's a big complicated subject. Note that you are unlikely to get as good a result with recycled materials as I got in this video - remember "garbage in garbage out".... Martin
Glad to see you back! Also, good to see you point out where others have made mistakes and where they can make improvements.
Mister, Its not only the others that made those mistakes - I made many of them myself in my very early days. So I guess I am really trying to pass on avoiding mistakes I have made by using others as examples.... Martin
@@olfoundryman8418 That's the only way one can improve, is by learning from their mistakes so that they don't make them again.
Martin good to see you posting again, your wisdom was missed. hope to see you at the molding bench.
Wayne, Yes its been too long. The moulding bench is still a way off and sadly maybe a never as the pain level on standing is about a 9 out of 10. there is though a possibility (I see about this tomorrow) that I may get that down to a 5 or even a 2 in which case the bench will be back on... Martin