Woohoo, I found another bedtime channel. Love watching stuff like this with relaxing narration as I fall asleep. Another good channel is Engels coach shop.
Good to see a foundry in action. Back in 1978 I went into an aluminum foundry to get an estimate on some parts for a 1940s model airplane engine. Fell told me "Yep, we can cast all those parts for about $8 (mind you, this was 1978)." When I asked him how much the patters would cost, he said "Oh, probly, about $1500." That's when I decided to make my own patterns. I was a machinist at the time, and later got into pattern making.
@Tabourba I'd be really surprised if the patterns 'wore out', if reasonably robust they should last for decades. It's only when used daily for weeks that they would get worn and/or damaged. Under such production, new production patterns on match plates would be made of aluminum or even cast iron. Likewise the core boxes.
This is fascinating stuff. I worked in an investment casting foundry for years and really enjoyed the entire process. My coworkers at the time called it hard meaningless work and I called it artwork, had a blast the entire time I was there.
Did those guys did the grind and cleanup operations? I have ceramic slurry, haven't had an opportunity to use it yet but investment is around the corner👍
I love your work Clarke.....been addicted to your channel since viewing Adam Booth on his channel...may your channel grow and grow, its well deserved....
Nice work! I worked in a Cupola foundry in the early 70's. Bigger stuff but the molders worked a long time so we could make good castings. Molds with both cores & chills were interesting to pour. Decided that the work was too hard & went back to school. That was probably my dad's idea when he got me that job! lol!!
Thanks and I have the highest respect for anyone that did or still does foundry work. I've worked most of my life as a machinist and then into the quality field. None of that can compare to all the chemistry, physics, design, engineering and dangers of foundry work. It's a different animal all together.
I’m very much enjoying watching and learning the tricks of sand casting. I’m most likely going to have a couple of pieces for a Monarch lathe I’m refurbishing I’ll need cast in a month or two and I’m planning to get in touch with you when I get to that point. Thanks for the videos in the meantime!
your skills are amazing seeing all the details of making a casting like this one with cores I have a deep appreciation for metal casters and always will !
This was a fascinating look at the process! I saw Emma making the patterns, but the cores and how it fits together make a lot more sense now. Thanks for filming it :)
Back in the early1970s when I was in high school we had a foundry in the metal shop. We couldn't do cast iron but we did a lot of aluminum, brass and bronze. One of the kids had a Hurst T shifter handle on his car, back then you had to buy the shifter and linkage to get the T handle so we borrowed his shift handle and copied it in brass for our hot rods.
another thing too I have seen in videos casting cores are sprayed with a slurry made of powder clay , powder graphite and water the slurry is thin enough to be used in a spray gun and it is painted on the surface of the cores to make them smooth
I enjoy watching you building the cores. Adam, Keith, and Laura all recommended your channel....they were right. It has been a pleasure to watch a skill I know nothing about! Thanks for sharing your skills!
Thanks and you are correct. I used to take foundry work for granted until I started doing it. I left out a lot in this video but tried to cover some of the important parts.
Clarke, I really enjoyed watching this. I must say, you're a braver man than I am. I thought casting brass was scary! Regards, Mark Presling. Queensland, Australia
Thanks my friend....Been doing casting for 40 some years now...No not iron but stuff in gold...l am a Gold Smith by triad....l use the lost wax way....Lost wax casting are highly accurate even down to the very very tiny detail so much that it is a perfect copy ...l really like watching you do your stuff...Thanks
Thanks Steve, what you do is fascinating as well. I have suspenda slurry and may actually use it for the first time in the next couple weeks. If so I'll do a video of that
Nice work Clarke, small castings with intricate cores are always a challange. Just wondering if you use seacoal dust in your sand. It sets up a nice gas front at the surface and prevents the sand burning in. Gives a nice finish to the surface and the sand brushes of easily. Cam
Thanks Cam and yes I do. I need to readjust the ratio because the sand used to come off clean in big cakes with very little brushing. Since there hasnt been fusion to the sand I haven't worried about it but I am finding it is going to soon need more added back in.
I think we used molasses in the sand then baked it in a mold. But the cores were hollow. The machine that made the cores shot the proper amount of mixture in the core mold. The mold was rotated around as it was heated. When the process was completed the mold was opened and the core was taken out of the mold. Some cores were solid and required lots of sand.
Yes ,we made the Corea with fine sand mixed with linseed oil and crude oil and powdered gum,i think the gum powder was also used in the food industry,the Cores were baked in an oven,they looked like differant shaped cakes,
Ian I often have to refer customers to Stuart when they ask me about casting some engines. They are not only the experts, they can produce the kits for a fraction of what I would charge. They have been around a long time and hope they can continue through the next century👍
That is really neat. I read up on it after you sent this to learn about Pierce. I see it began in the 1840's and unfortunately shut down in 2002. Like white chapel in London, it makes me ill to see something go for so long and then fade away
Excellent video. Please why did you reheat the cast parts after casting them? All I can think of is stress relief but then why? Thank you for a very informed video starting from scratch through to completion.
That looks very professional and pretty freaking accurate, also higher effort, and with great results, the complexity and need for accuracy is incomparable to low stress cast pieces that get maschined a lot /hobbyist pieces or cast iron art pieces you sometimes make , its beautiful to see this kind of crasftsmanship with these more complex and larger parts Also i got to ask Have you ever cast any combined material castings so far? - like useing a ribbed pipe or cup cast iron casting as core of a aluminum casting like for a replacement engine cylinder or cylinder head blank of a engine or cast lead bronze into a cast iron pieces bearing eyelet also can you preheat/ceramic coat your molds and what are the possible benefits&downsides of petrolbond for cast iron - please can you do a basics of castings video, maybe show some examples of fuckups and how to prevent them, different mold materials and their pros and cons like lost wax with dipped ceramic mold - maybe also shrinkage and solidification times for different materials
Parabéns pelo canal sou novo logo vou ser um bom profissional nesta área muito bom os video estou muito feliz por aprender uma linda profissão desta com o desemprego agora estou partindo para outra profissão como eu trabalho com artesanato mim ajudar bastante está profissão muito bom parabéns 👏👏👏👏 agora vou acompanhar todos os vide quero entra nesta área ser deus quiser
Holman I'm not sure I fully understand your question. If you run it at 600c you should do just fine but don't hold it, pour it as it reaches that or you will develop porosity
Jim I used an additional bed of sand on the drag side because the shaft that protrudes from that side was almost as high as the flask itself. It needed more of a sand barrier. Cheek molds are what flask containing more than two sections are generally called but this section wasnt actually applied to a molding technique
Rarely do I do bronze. Bronze requires different temps, and some other things to pour efficiently. Usually I farm that out to Green Foundry, they are better setup for bronze
34:25 - and _this,_ ladies and gentlemen, is another reason for all that protective gear. I think this droplet of hot iron would burned straight through your flesh, had it hit you.
Look back where you were preparing more media. Were your rations correct? Looked like your second ingredient addition was based upon total weight and not on material added,,,,if it makes any difference.
A lot of work, preparation but its a labor of love and the end product is beautiful. Just curious, why not make the smaller cores out of candle wax or styrofoam materials as these won't need removal of the core in the sand.
I had replied to you earlier. Again thanks so much for the offer but I have a good source here. If we were closer I'd be glad to take you up on your offer
Woohoo, I found another bedtime channel. Love watching stuff like this with relaxing narration as I fall asleep. Another good channel is Engels coach shop.
Good to see a foundry in action.
Back in 1978 I went into an aluminum foundry to get an estimate on some parts for a 1940s model airplane engine.
Fell told me "Yep, we can cast all those parts for about $8 (mind you, this was 1978)."
When I asked him how much the patters would cost, he said "Oh, probly, about $1500."
That's when I decided to make my own patterns.
I was a machinist at the time, and later got into pattern making.
@Tabourba I'd be really surprised if the patterns 'wore out', if reasonably robust they should last for decades.
It's only when used daily for weeks that they would get worn and/or damaged.
Under such production, new production patterns on match plates would be made of aluminum or even cast iron.
Likewise the core boxes.
This is fascinating stuff. I worked in an investment casting foundry for years and really enjoyed the entire process. My coworkers at the time called it hard meaningless work and I called it artwork, had a blast the entire time I was there.
Did those guys did the grind and cleanup operations? I have ceramic slurry, haven't had an opportunity to use it yet but investment is around the corner👍
I love your work Clarke.....been addicted to your channel since viewing Adam Booth on his channel...may your channel grow and grow, its well deserved....
After all that work, looks like the pressure is now on Emma. Great views of the processes.
Cheers, Gary
Nice work! I worked in a Cupola foundry in the early 70's. Bigger stuff but the molders worked a long time so we could make good castings. Molds with both cores & chills were interesting to pour. Decided that the work was too hard & went back to school. That was probably my dad's idea when he got me that job! lol!!
Thanks and I have the highest respect for anyone that did or still does foundry work. I've worked most of my life as a machinist and then into the quality field. None of that can compare to all the chemistry, physics, design, engineering and dangers of foundry work. It's a different animal all together.
I’m very much enjoying watching and learning the tricks of sand casting. I’m most likely going to have a couple of pieces for a Monarch lathe I’m refurbishing I’ll need cast in a month or two and I’m planning to get in touch with you when I get to that point. Thanks for the videos in the meantime!
Looking forward to hearing from you👍
Great work Clarke, the attention to detail is outstanding!
Thank you👍
your skills are amazing seeing all the details of making a casting like this one with cores I have a deep appreciation for metal casters and always will !
just getting home to watch this now. getting excited now!! thanks for the shout out.
Emma you did an excellant job on these patterns and core boxes👏
@@windyhillfoundry5940Foundry ive just realised what I think might be the issue with the cores.. lol. too late now.
@@EmmaRitson I have an idea what was going on too. When I get back next week I'll do some careful measuring
I like the plastic bag for mixing the core sand. I will try that next time I make some cores.
I'm always amazed at the skill it takes to do this kind of work. Great job keep up the good work.
I always love seeing the castings done.
Me too👍
Quickly becoming one of my favorite channels. ✌️
Thank you👍
This was a fascinating look at the process!
I saw Emma making the patterns, but the cores and how it fits together make a lot more sense now. Thanks for filming it :)
Glad you enjoyed it Adam👍
Back in the early1970s when I was in high school we had a foundry in the metal shop. We couldn't do cast iron but we did a lot of aluminum, brass and bronze. One of the kids had a Hurst T shifter handle on his car, back then you had to buy the shifter and linkage to get the T handle so we borrowed his shift handle and copied it in brass for our hot rods.
I really enjoy watching you work, really like your attention to detail. Thanks for a nice video, keep it coming.
another thing too I have seen in videos casting cores are sprayed with a slurry made of powder clay , powder graphite and water the slurry is thin enough to be used in a spray gun and it is painted on the surface of the cores to make them smooth
I enjoy watching you building the cores. Adam, Keith, and Laura all recommended your channel....they were right. It has been a pleasure to watch a skill I know nothing about! Thanks for sharing your skills!
Hey WINDY Hill Foundry
Y’all doing a great job !!!
Enjoyed the video.
Keep it coming
Thanks!
Great video Clarke, keep'em coming.
Thank you Richard👍
Amazing amount of effort and detail!
Hi Clarke, great and interesting video. So many processes involved within foundry work. Its not an easy craft!.....Regards MachineNZ
Thanks and you are correct. I used to take foundry work for granted until I started doing it. I left out a lot in this video but tried to cover some of the important parts.
Man there's a lot of work just preparing to casting a part. Great job I would be very satisfied with the part.
@MichaelKingsfordGray WTF are you talking about?
Absolutely great job. Thanks for sharing.
Amazing work, you’re an artist!
Thank you and glad you enjoyed it👍
good job, hot work area,nice looking parts
Clarke, I really enjoyed watching this. I must say, you're a braver man than I am. I thought casting brass was scary!
Regards, Mark Presling. Queensland, Australia
That's Mark, glad you enjoyed it👌
Nice to see so much skill in casting!
Thanks my friend....Been doing casting for 40 some years now...No not iron but stuff in gold...l am a Gold Smith by triad....l use the lost wax way....Lost wax casting are highly accurate even down to the very very tiny detail so much that it is a perfect copy ...l really like watching you do your stuff...Thanks
Thanks Steve, what you do is fascinating as well. I have suspenda slurry and may actually use it for the first time in the next couple weeks. If so I'll do a video of that
@@windyhillfoundry5940 Be looking forward to it Thanks for the return text...!
Nice work Clarke, small castings with intricate cores are always a challange. Just wondering if you use seacoal dust in your sand. It sets up a nice gas front at the surface and prevents the sand burning in. Gives a nice finish to the surface and the sand brushes of easily.
Cam
Thanks Cam and yes I do. I need to readjust the ratio because the sand used to come off clean in big cakes with very little brushing. Since there hasnt been fusion to the sand I haven't worried about it but I am finding it is going to soon need more added back in.
Good video Clarke. Package on its way to you.
Thanks Mike, glad you enjoyed it. Looking forward to the package👍
I think we used molasses in the sand then baked it in a mold. But the cores were hollow. The machine that made the cores shot the proper amount of mixture in the core mold. The mold was rotated around as it was heated. When the process was completed the mold was opened and the core was taken out of the mold. Some cores were solid and required lots of sand.
Thanks James👍
Watching this older video again reminds me I do not recall if Emma got that engine to run or run right.🤔
NICE SEEING THIS PROCESS! GREAT JOB !YOU ARE GOOD AT WHAT YOU DO SIR ! IT'S A LOT OF WORK'
Thanks, I wish there were easier ways for sure
@@windyhillfoundry5940 Then everyone would do it. I am sure there is enough competition as it is. Great video
it's more than ok! , those "issues" 0:50 can be easy fixed with welding filling. Nice job!
Yes ,we made the Corea with fine sand mixed with linseed oil and crude oil and powdered gum,i think the gum powder was also used in the food industry,the Cores were baked in an oven,they looked like differant shaped cakes,
Stuart engines are made down here in Dorset still in their place over at Bridport and still going strong I believe :)
Ian I often have to refer customers to Stuart when they ask me about casting some engines. They are not only the experts, they can produce the kits for a fraction of what I would charge. They have been around a long time and hope they can continue through the next century👍
I was watching intently. You got my undivided attention when your niece arrived. 😉
Say HI to Keith Rucker, his recommendation of your channel was a good deed.
Nice can't wait to see Emma start working on them
Me too👍
Nice trick using the nails as core pins...always wondered how you got asymmetrical cores to stay put.
Yes most cores have a mass to keep them in place. This couldn't be done though
I was a Core maker un pierces foundry in wexford ireland in the early 1970s,they agri machinery
That is really neat. I read up on it after you sent this to learn about Pierce. I see it began in the 1840's and unfortunately shut down in 2002. Like white chapel in London, it makes me ill to see something go for so long and then fade away
Can you make hollow civil war cannon balls with that core technology? I always wondered how they did it back then.
Yes, I believe the old binders they used were molasses and some other things they would bake
Windy Hill Foundry thanks man. Just discovered you and subbed
Great content thanks for sharing
Very informative and well done.
Progress mate!! Thanks for sharing
Thanks, glad you enjoyed it. Didnt know the UK was up this late😁
I’m in Australia mate :-)
@@JBFromOZ M, I apologize, I knew that. I was running on very little sleep yesterday🤣
No apologies needed mate, you’re a legend and I’m glad to see your work
i just watched this again. I am sorry. thats all I can say lol. wow thats a challenging mould.
Would have went better if I could have nailed it the first round🤣
Time for a dumb question... Why couldn't you take some of the liquid sodium silicate and use it like a glue to fix the crack in core?
I've actually tried that but without recompressing it doesn't work well
Love your work :)
Thanks Clive👍
Excellent video. Please why did you reheat the cast parts after casting them? All I can think of is stress relief but then why? Thank you for a very informed video starting from scratch through to completion.
Bernie you are correct. I stress relieve all iron castings.
was watching Abom79 working your right angles. guess I will sub up and hit the bell.
Great looking!
That looks very professional and pretty freaking accurate, also higher effort, and with great results, the complexity and need for accuracy is incomparable to low stress cast pieces that get maschined a lot /hobbyist pieces or cast iron art pieces you sometimes make , its beautiful to see this kind of crasftsmanship with these more complex and larger parts Also i got to ask Have you ever cast any combined material castings so far? - like useing a ribbed pipe or cup cast iron casting as core of a aluminum casting like for a replacement engine cylinder or cylinder head blank of a engine or cast lead bronze into a cast iron pieces bearing eyelet also can you preheat/ceramic coat your molds and what are the possible benefits&downsides of petrolbond for cast iron - please can you do a basics of castings video, maybe show some examples of fuckups and how to prevent them, different mold materials and their pros and cons like lost wax with dipped ceramic mold - maybe also shrinkage and solidification times for different materials
Thanks for the compliment and I hope to cover all your questions in upcoming videos 👍
Fascinating.
Pretty amazing👍👍👍👍👍👏🏻👏🏻👏🏻
Excellent video. I have two parts I need made for my two post drill press's. I am going to email you to see if you can make them. Thanks
Sure, you can can contact me at
Clarke@windyhillfoundry.com
never seen a machine like this
Is the purpose of "stress relieving" only to relieve internal stresses or is it also to transform any chilled (hard) areas into softer grey cast iron?
It is to relieve the stresses.
thats very interesting, i didnt know that cast iron has a low enough surface tention and viscosity to rise up into ventholes
At the right temp Iron has the fluidity of water
what is that you wearing during casting that covers the top part of your boots and your pants leg
Those are spats, keeps the iron from running down in my boots if there's a splash
@@windyhillfoundry5940 oh ok i was wondering i am back yard foundry type of guy always worried about the metal splashing
Parabéns pelo canal sou novo logo vou ser um bom profissional nesta área muito bom os video estou muito feliz por aprender uma linda profissão desta com o desemprego agora estou partindo para outra profissão como eu trabalho com artesanato mim ajudar bastante está profissão muito bom parabéns 👏👏👏👏 agora vou acompanhar todos os vide quero entra nesta área ser deus quiser
How do I do for the aluminium to be more liquid? What can I use?..my pieces do not fit well the aluminum solidifies very quickly...Thanks for help me
Holman I'm not sure I fully understand your question. If you run it at 600c you should do just fine but don't hold it, pour it as it reaches that or you will develop porosity
@@windyhillfoundry5940 Ok thank you very much
How much does something like this cost as a 1 off casting? Even a rough range would be very handy to know
Big Bucks for you! To much work, I hope are only making one!
There is the cope and the drag, what is the third, or middle form called? The befuddlement?
Jim I used an additional bed of sand on the drag side because the shaft that protrudes from that side was almost as high as the flask itself. It needed more of a sand barrier. Cheek molds are what flask containing more than two sections are generally called but this section wasnt actually applied to a molding technique
@@windyhillfoundry5940 I was right. Thanks Clark.
What gas do you use on the cores ? Carbon dioxide ?
Stay safe and healthy .
Enjoyed the video . :-)
Wyr
God bless
Yes
Yes
is there any problem with copying a Stuart model or is it no longer in production?
What pressure do you run on the CO2?
Hi, I have no set pressure for gassing. On large cores I Jack the pressure up until I hear it
i know you do cast iron but do you ever do bronze?
Rarely do I do bronze. Bronze requires different temps, and some other things to pour efficiently. Usually I farm that out to Green Foundry, they are better setup for bronze
Very nice...
Thanks for sharing
What is the effect of heat treating it in the kiln after casting? Reduce grain structure? Anneal?
This relieves the iron of any stress. Without it the iron will move as its machined.
34:25 - and _this,_ ladies and gentlemen, is another reason for all that protective gear. I think this droplet of hot iron would burned straight through your flesh, had it hit you.
Yes you would be correct👍
Look back where you were preparing more media. Were your rations correct? Looked like your second ingredient addition was based upon total weight and not on material added,,,,if it makes any difference.
Was surprised to hear you using metric weights, but l guess that is what everyone in the world uses except for the US.
A lot of work, preparation but its a labor of love and the end product is beautiful. Just curious, why not make the smaller cores out of candle wax or styrofoam materials as these won't need removal of the core in the sand.
The problem with that is they need to remain intact until the iron freezes.
Can "lost foam" method be used for this?
I have never used foam so I can't answer that. I would think no.
20/20
Let's try Sodium Silicate AIRCRETE cores.
ARE YOU SELLING THE STUART 400 CASTING KITS?
I can but Emma is the one you would need to talk to
i notice you use looks like a lot of brake rotors i am in southeast alabama could start saving them instead of dumpster if interested
I had replied to you earlier. Again thanks so much for the offer but I have a good source here. If we were closer I'd be glad to take you up on your offer
Haha! I had to laugh out loud at the ISO 9001 joke :)
As long as you poop consistently, same time and amount every day, you can be ISO certified too!
I understand completely if I couldn’t vent then my wife would probably have nothing to do with me lol
is gooooooooooooooood
30:20 *THAT* was a cool voice. almost sounded human.
good
Pouring that must have been heavy
Yes sir, my rotor supplier asked me why I didn't get into making things out of styrofoam😁
I have a kleptomaniac at my house too 😂
Labor of Love!! Good looking Casting.Miss my days working in a foundry.
Each day is definitely a challenge👍
Whats the purpose of the CO2 flooding? I mean...I want to say it's an oxidation thing but that doesn't....make sense really....
This is a reaction that creates the binding of the sodium silicate when gassed with co2
Man that would be a bad day for ol Jake if he stuck his nose in that hot metal lol.
Hi
لظمم
What does the gas do to the sand?
The CO2 has a chemical reaction with the sodium silicate that hardens it