Very hard to make stuff with molds that you have to take out. I would only use plaster if I used wax and melted it out, otherwise trying to split the plaster in two halfs would be awful
+KlixTrio It depends on the shape of the item, but you're right. I prefer it over sand mostly because of the MUCH better surface finish and the fact that I have a method for making easy copies of the original that's cheaper than using wax (which is quite expensive in fact).
Your furnace oozes with profound efficiency and a hint of "Man-Cave." I love the design of your cast, and as I begin the journey of a Blacksmith, I will be using one of your models in my first set. All of your videos are enthralling and informative; Thank you.
Great explanation on the process and amazing results. Five years later and this is still the best quality casting I've seen on youtube. I used green sand/petrobond like this to make a sterling silver pendant for my wife back around 2009-ish. TH-cam was not yet the incredible resource it is today. I modeled the piece by hand in wax and then followed this same process with amazing results. The kicker is, it was a key with a heart shaped top, and the key is a fully functional duplicate for a master brand lock she uses for a memory box, except entirely sterling silver now.
+Kelly Hawkins One of the better ones I have seen personally... You didn't see the fist pumps and cartwheels after I turned off the camera! The other four sets turned out very well too!
I love how you take projects from start to finish... most of the time! Still waiting to see how that domino box and domino's turn out! ;) Edit: Oh and I loved the extra info at the end. That question about the sand being reusable was burning a hole in my head every time I watched your video's. I can't imagine this particular sand is inexpensive by comparison. On the matter of mixing have you seen MyFordBoy's sand reconditioning process? Thank you.
I can say that you are on par with the few Masters that I have had the pleasure of working near. A rarefied air is forming around your work. I do not particularly care for that particular combination of brushed aluminum, with light hardwood, normally. It works a bit for me here. There is no accounting for taste, and mine does bot run that way; but you are drawing me in... such is your refinement of form, fit, function, and aesthetic. Having said all that, cast those in a brass, bronze, copper, or a darker pewter; and I am sold as a neo-classic all day. Bravo.
This whole process looks rewarding through out. The more I watch the happier I become for the results you are getting. You have got a talent for this thats for sure.
Ummm no one has pointed out that he has a CNC machine. So why waste time making a mold, casting and finishing. When he could easily have just cast a block on Ali and set the CNC to cut it. Would he perfect in every way then. Also all waste can be melted into a new block of Ali for next project. Seems like a massive waste of time. Looks nice though, but CNC products are better
+Nik A False. Actually it has been mentioned a few times! CNC part would actually require more finishing after a much longer machine time because it is easier to sand Renshape than Aluminum. If it took 2 hours to machine the pattern, it might take 10 hours to machine the aluminum. CNC chips can be melted down, but the alloy you would use for machining isn't good for casting. I made 5 sets of these so far so there is a huge advantage for multiples. 2 hours to machine and finish pattern and one hour to ram up and cast (total of 7 hours for 5 copies) vs 10 hours per CNC part (total of 50 hours of machine time for 5 copies). CNC result would likely be less smooth unless step over was set really small, drastically increasing machine time.. I suppose it would require less physical labor, but CNC isn't always better!
Right on the money. When producing a large number of parts you would save more time and money when casting versus machining. If you want to factor in the cost of machining versus casting in a manufacturing environment you save way more money when casting. Not to mention the cost of bits for cutting aluminum which would need to be replaced as they dull. Also you waste a lot less aluminum when casting since your sprus and risers etc can be remelted down for the next batch run, whereas aluminum chips off the cnc need to be properly recycled by a plant and wouldn't be able to be reused especially by a DIY home hobbyist. Trust me I have tried melting down chips from a cnc, it all just turns to slag.
In a prior career I ran a cnc shop and contracted programming to several. If that part were machined from bar stock you could not fixture it with 4 wood screws. You cant just "drop a cast ingot" on the table of anything and expect it to stay there. If you had any appreciable metal removal rate the gantry style router used here would not be rigid enough to make any money. To not post finish it your step over would be so small you would never make money. Casting this part is the right choice. If you were talking thousands of pieces than sand would not the the most economical. Even if you were to machine it after casting getting it near net would be the best production cost. Though a machined after cast 3d shape would likely require additional steps to ensure porosity cannot occur.
I'm blown away by the quality of all the projects you do. I have always prided myself on being detail oriented but watching you makes me feel like I definitely need to step up my game. Even your videos are edited so well that I don't find the need to scrub through. Thank you for the inspiration!
+Ape's metalshop Thanks! Before I was doing a separate video for the pattern when I cast something. Very few people watch the first parts although that is where all the work is!
It looks like that was a TON of work to get those pulls made... TOTALLY worth it though. They look amazing. Thanks for bringing us along for the journey.
Brian, you do amazing work, especially your attention to detail. LOVE watching your videos. The modern organic shapes you come up with is my style! Please keep them coming.
boy.. I wanted to cast aluminum but I think I just watched the holy grail and will never compare.. that's amazing and beautiful very nice work! super jelous
I've paid big money to professional foundries and haven't always gotten as nice results as what you've produced. Beautiful design, I also enjoy how you've allowed the plywood edge to become a pleasing design element. I'm a little concerned about putting those fasteners into the edge of the plywood and how it may come back to haunt you if it were to cause the fronts to split. The bottom of your match plate is empty, maybe you have some room to extend some material down to form a more stable mount. But what the hell do I know I make machines where I'm always worried about people intentionally breaking them and not beautiful home furniture like this. Awesome work Brian!
The nicest furniture handle I ve ever seen... Such display of craftmanship and talent make us other makers feel humble. Really impressed by all of your videos I 've watched so far... Congrats!
Wow!!! Impressive!!!It reminds me of working with Aircraft parts when I worked at Boeing Company years ago!!! Beautiful work.I like watching you Leather Working videos also.
Wow, Brian. Your work is spectacular! I have a company that "makes things", and we strive for the level of work you seem to consistently put forth. Bravo.
great video production quality... my fav transition is when you're testing the drawers and sliding them, and the finished cabinet appears ! I really like your spru method with the funnel and thin sink plumbing riser what a perfect funnel shape result. The solid craftsmanship of the beer ked forge shows your years of honing your skills. hat tipped
love the design, one suggestion, you could put a lip at the back of the pull and locate it in a rebate on the inside top edge of the drawer, then you could hide the fastenings of the bottom drawer
Not to knock *any* of your other projects at *all*, but these are the most beautiful objects I've seen come out of your channel. They're perfect. Just... Bam. Perfect. *high five*
Could you do video on your tongs that you use. Never seen a set that grab the crucible and allow you to pour with the same set. Your work is always top notch. Between you and myfordboy a person can learn a lot. Keep them coming
I have to say, you do an amazing job in your videos. I love how detailed they are even the part at the end where you show what to do with the sand. I would love to see more videos!
OMG !! Das ist das genialste was ich auf TH-cam gesehen habe und dazu noch so schöne Maschinen ! Thank you very much for your Video. Greetings from Germany
Nice work fresh petrobond mix gives such nice castings, Instead of a expensive muller I use a large harbor freight cement mixer I have a couple round ingots in it and just throw my sand/petrobond mix in it after each casting then let it run for about 10 min depending how many pours I'm doing I put a little non detergent oil in it when it gets dry and add some fresh petrobond clay to it when it gets weak.
You are a true credit to your work mate. amazing as always! I'm halfway through building a keg foundry much like yours and have been using your videos for pre-research for being able to extend what I'm able to build for my prop business.
Brian, use a sieve for "re-mixing" the casting sand. It's the same type of sieve used for running a gradation in soils. Just like playing with beach sand as a child! Try using a #4 or #8 as a 16 may be too small. They come in 8" diameter rings and are used in the geotechnical engineering and testing industry. ~Loren~
Video well done. I'll be using it for my materials and processing class to illustrate the sand casting technique. Your drawer pulls are very nice as well!
That is without a doubt the most perfect casting I've seen on TH-cam. Excellent craftsmanship. Great job.
Actually plaster castings have an even better surface finish. They're a bit more uncomfortable to work with though.....
Very hard to make stuff with molds that you have to take out. I would only use plaster if I used wax and melted it out, otherwise trying to split the plaster in two halfs would be awful
+KlixTrio It depends on the shape of the item, but you're right. I prefer it over sand mostly because of the MUCH better surface finish and the fact that I have a method for making easy copies of the original that's cheaper than using wax (which is quite expensive in fact).
+CoolKoon Could you share your method with us then ? It could be really helpful !
Search up green sand casting. It's not the best sand method, but its cheap and works pretty damn well.
Bloody hell, that's the best home-brew casting that I've seen on youtube
Awesome watching you work! Thanks for posting.
Hey Zack, good to see you here ! 😄
This is one of the more well produced casting videos I've seen. Thanks Brian!
Какой вы используете песок?
Your furnace oozes with profound efficiency and a hint of "Man-Cave." I love the design of your cast, and as I begin the journey of a Blacksmith, I will be using one of your models in my first set.
All of your videos are enthralling and informative; Thank you.
I worked with Renshape at my old job. Once you use it, its hard to go back. Watched this for the casting. Very inspirational.
The cast quality is impressive. Bravo!
+Carlos Pitcher Thanks! Like I said, it was better than I expected!
Your attention to detail and level of skill is phenomenal. Thank you Brian for sharing it with us.
Unbelievably cool. Wow. And the casting quality was just off the charts. Well done!
Great explanation on the process and amazing results. Five years later and this is still the best quality casting I've seen on youtube. I used green sand/petrobond like this to make a sterling silver pendant for my wife back around 2009-ish. TH-cam was not yet the incredible resource it is today. I modeled the piece by hand in wax and then followed this same process with amazing results. The kicker is, it was a key with a heart shaped top, and the key is a fully functional duplicate for a master brand lock she uses for a memory box, except entirely sterling silver now.
Awesome story, thank you for sharing this!
awesome!! unbelievable quality!! ^^
+Nicolas Danelon Thanks!
I think that is the best looking raw cast I've seen on TH-cam.
+Kelly Hawkins One of the better ones I have seen personally... You didn't see the fist pumps and cartwheels after I turned off the camera! The other four sets turned out very well too!
I love how you take projects from start to finish... most of the time! Still waiting to see how that domino box and domino's turn out! ;)
Edit: Oh and I loved the extra info at the end. That question about the sand being reusable was burning a hole in my head every time I watched your video's. I can't imagine this particular sand is inexpensive by comparison. On the matter of mixing have you seen MyFordBoy's sand reconditioning process?
Thank you.
you sir are one hell of a craftsman.. its good to see those skills are still alive and well..
Awesome as usual.
+Brooks Nelson Thanks!
Did you happen to read my email in regards to the MDF machine?
I've just binge watched so many of your casting videos! I love your attention to detail and quality of your work. Thanks
what crucible holder do you use
Such a beautiful cast, didn't know it was possible to make them that smooth directly from casting. Great job!
honestly, i would like to know reason of some dislikes here !
you are the reason
Dis-i-like
He makes the rest of us look like lazy bums who'd rather watch youtube than get off our fat arses and actually do something productive?
@@johnalexander2349 that's all you man. I watch these video to learn and they're very interesting.
I can say that you are on par with the few Masters that I have had the pleasure of working near. A rarefied air is forming around your work. I do not particularly care for that particular combination of brushed aluminum, with light hardwood, normally. It works a bit for me here. There is no accounting for taste, and mine does bot run that way; but you are drawing me in... such is your refinement of form, fit, function, and aesthetic. Having said all that, cast those in a brass, bronze, copper, or a darker pewter; and I am sold as a neo-classic all day.
Bravo.
Yeah, some people are brass and oak and then there are those with taste. Seriously, brushed copper may look pretty cool with a birch ply
Skookum as frig!
+makethingz Thanks bro! Keep your stick on the ice :)
This whole process looks rewarding through out.
The more I watch the happier I become for the results you are getting.
You have got a talent for this thats for sure.
Ummm no one has pointed out that he has a CNC machine. So why waste time making a mold, casting and finishing. When he could easily have just cast a block on Ali and set the CNC to cut it. Would he perfect in every way then. Also all waste can be melted into a new block of Ali for next project. Seems like a massive waste of time. Looks nice though, but CNC products are better
+Nik A False. Actually it has been mentioned a few times! CNC part would actually require more finishing after a much longer machine time because it is easier to sand Renshape than Aluminum. If it took 2 hours to machine the pattern, it might take 10 hours to machine the aluminum. CNC chips can be melted down, but the alloy you would use for machining isn't good for casting. I made 5 sets of these so far so there is a huge advantage for multiples. 2 hours to machine and finish pattern and one hour to ram up and cast (total of 7 hours for 5 copies) vs 10 hours per CNC part (total of 50 hours of machine time for 5 copies). CNC result would likely be less smooth unless step over was set really small, drastically increasing machine time.. I suppose it would require less physical labor, but CNC isn't always better!
Right on the money. When producing a large number of parts you would save more time and money when casting versus machining. If you want to factor in the cost of machining versus casting in a manufacturing environment you save way more money when casting. Not to mention the cost of bits for cutting aluminum which would need to be replaced as they dull. Also you waste a lot less aluminum when casting since your sprus and risers etc can be remelted down for the next batch run, whereas aluminum chips off the cnc need to be properly recycled by a plant and wouldn't be able to be reused especially by a DIY home hobbyist. Trust me I have tried melting down chips from a cnc, it all just turns to slag.
If this was true, everything at harbor freight would be CNC machined, and not cast. Derp.
In a prior career I ran a cnc shop and contracted programming to several.
If that part were machined from bar stock you could not fixture it with 4 wood screws. You cant just "drop a cast ingot" on the table of anything and expect it to stay there.
If you had any appreciable metal removal rate the gantry style router used here would not be rigid enough to make any money.
To not post finish it your step over would be so small you would never make money.
Casting this part is the right choice. If you were talking thousands of pieces than sand would not the the most economical.
Even if you were to machine it after casting getting it near net would be the best production cost. Though a machined after cast 3d shape would likely require additional steps to ensure porosity cannot occur.
Cracking surface finish as-cast! Total work of art once you're done with the sanding.
I'm blown away by the quality of all the projects you do. I have always prided myself on being detail oriented but watching you makes me feel like I definitely need to step up my game. Even your videos are edited so well that I don't find the need to scrub through. Thank you for the inspiration!
I like how well you have made the whole casting process. Pleasant to watch.
+Ape's metalshop Thanks! Before I was doing a separate video for the pattern when I cast something. Very few people watch the first parts although that is where all the work is!
this is probably one of the best Aluminum casting videos I have seen. well done.
You are so fortunate to have that kind of skill--just love the foundry part of it.
It looks like that was a TON of work to get those pulls made... TOTALLY worth it though. They look amazing. Thanks for bringing us along for the journey.
+Greg's Garage Thanks for the comment! Not that hard at all... The biggest PITA is ramming up the sand. I have made 5 sets of them now!
Always wise to think about the future when making molds, models, jigs, etc. You never know when they can prove useful, again.
Those handles and that cabinet design are sick.
A craftsman at work,a joy to watch
The Time lapse part of the video along with the audio is sooo Satisfying to watch..!
Brian, you do amazing work, especially your attention to detail. LOVE watching your videos. The modern organic shapes you come up with is my style! Please keep them coming.
+Jeffrey I Will do!
Excellent craftsmanship! Well done!
Your videos are very enjoyable to watch. I'm sure many people are learning a lot from them. Please keep posting.
boy.. I wanted to cast aluminum but I think I just watched the holy grail and will never compare.. that's amazing and beautiful very nice work! super jelous
+Steve Simons Thanks!
i remember watching you build that cnc years ago, good to see its still working away, love the casting.
Thanks! Been a crazy journey!
I watched this a while back. Had to watch it again. Your expertise is inspiring, I have a few projects that I want to try. Thanks !
Time to build a ball mill to pulverize the burned Petrobond.
Beautiful design, routing, foundry work, finish work, drawer work, elegant par deluxe.
+boogerhead0 You are correct, sir. Thank you for the comments!
I've paid big money to professional foundries and haven't always gotten as nice results as what you've produced. Beautiful design, I also enjoy how you've allowed the plywood edge to become a pleasing design element. I'm a little concerned about putting those fasteners into the edge of the plywood and how it may come back to haunt you if it were to cause the fronts to split. The bottom of your match plate is empty, maybe you have some room to extend some material down to form a more stable mount. But what the hell do I know I make machines where I'm always worried about people intentionally breaking them and not beautiful home furniture like this. Awesome work Brian!
this is not just craftsmanship it also art
The nicest furniture handle I ve ever seen...
Such display of craftmanship and talent make us other makers feel humble.
Really impressed by all of your videos I 've watched so far... Congrats!
possibly the nicest looking drawer pulls ever ... not sure I have that patience ... I respect it in others
That Renshape makes beautiful uniform chips, great for machining.
I heart birch plywood.
Wow!!! Impressive!!!It reminds me of working with Aircraft parts when I worked at Boeing Company years ago!!! Beautiful work.I like watching you Leather Working videos also.
those drawer handles looked beautiful!
Love the level of design and modeling that goes into all your projects.
Wow! Those came out great. Process was really fun to watch.
Love the finish to the metal. Simple and Elegant.
Wow, Brian. Your work is spectacular! I have a company that "makes things", and we strive for the level of work you seem to consistently put forth.
Bravo.
Those, sir, are absolutely beautiful!
+Paul Frieden Thank you, sir.
Beautifully done. Those pulls, if bought commercially and if you could get them, would cost a fortune.
Beautiful artisan work. You have created some lovely, organic, flowing curves in those handles.
+Joanne Lowery Thank you!
great video production quality... my fav transition is when you're testing the drawers and sliding them, and the finished cabinet appears ! I really like your spru method with the funnel and thin sink plumbing riser what a perfect funnel shape result. The solid craftsmanship of the beer ked forge shows your years of honing your skills. hat tipped
Fabulous craftsmanship and attention to detail!
love the design, one suggestion, you could put a lip at the back of the pull and locate it in a rebate on the inside top edge of the drawer, then you could hide the fastenings of the bottom drawer
Not to knock *any* of your other projects at *all*, but these are the most beautiful objects I've seen come out of your channel. They're perfect. Just... Bam. Perfect. *high five*
Those are beautiful. And a beautiful piece, as well. I'm building more and more plywood furniture. I love the way it looks. Thanks for the vid.
+Ajey Thanks for the comment! I have a huge plywood furniture project coming up...
The surface quality is awesome for a casting !
+GogogoFollowMe Thanks! I was super happy when I shook it out!
What a beautiful cast
Man, you do have a good imagination combined with good craftsmanship!
+Kacsa Manovilág thank you very much!
Absolutely stunning. What a great demonstration of different skills brilliantly executed.
If I had an milling machine I would also connect the stereo to the power button. Awesome!
The casting was so smooth! Amazing! 😲
Could you do video on your tongs that you use. Never seen a set that grab the crucible and allow you to pour with the same set. Your work is always top notch. Between you and myfordboy a person can learn a lot. Keep them coming
I have to say, you do an amazing job in your videos. I love how detailed they are even the part at the end where you show what to do with the sand. I would love to see more videos!
What a great vid, one of the cleanest molds I've seen, and the results are suitably impressive.
+Merv Thanks!
humm this guy designs about as good as I do... I am impressed... specially with the style... ... love the metal casting.... thumbs up!
+Robert Ostman Hey thanks!
Really nice casting, good job !!
I'm a simple guy, when i see good job, i say good job.
+Yoldark Thank you!
The finish work is most excellent!
I loved the bit at the end about the burnt sand. I'm looking forward to your video of a DIY SAG Mill. :)
Your channel is always one that I look forward to new content from. Awesome video.
OMG !! Das ist das genialste was ich auf TH-cam gesehen habe und dazu noch so schöne Maschinen ! Thank you very much for your Video. Greetings from Germany
Yay beatiful work. Makes a change from people pouring alu muffins!
Now that folks is some great craftmanship. Strangely I got movements over this :D
The cast is amazing, as usual, but I'm really digging the design of that end table (or whatever you'd call it). That thing is beautiful.
+Keeling Design & Media Vörkbensh (you'll understand why soon). It is one of my new shop tables. :)
Nice work fresh petrobond mix gives such nice castings, Instead of a expensive muller I use a large harbor freight cement mixer I have a couple round ingots in it and just throw my sand/petrobond mix in it after each casting then let it run for about 10 min depending how many pours I'm doing I put a little non detergent oil in it when it gets dry and add some fresh petrobond clay to it when it gets weak.
You are a true credit to your work mate. amazing as always! I'm halfway through building a keg foundry much like yours and have been using your videos for pre-research for being able to extend what I'm able to build for my prop business.
Your videos are very well made and those handles are very beautiful.
It's really a piece of art!
I hope next year when I decorate my house, can do the same work like yours.
This next level craftsmanship! Amazing
Very nice work. Enjoyed the video and the passion you have for a well refined finished product. Inspiring! Thanks for sharing.
best DIY YT aluminium cast I ve seen by far D:
Love your videos! Seems like you have a factory in your backyard as all tools are right under your fingertips :)
Excellent video. I loved the design of the handle.
Very impressive craftsmanship! Your design is beautiful as well.
+Don Z Thank you!
Brian, use a sieve for "re-mixing" the casting sand. It's the same type of sieve used for running a gradation in soils. Just like playing with beach sand as a child! Try using a #4 or #8 as a 16 may be too small. They come in 8" diameter rings and are used in the geotechnical engineering and testing industry. ~Loren~
+Loren G Thanks for the suggestion! Might just work.
Wow, everything about this is absolutely beautiful!
Great video man and great job on the pulls! I loved most how you added all those cool sound effects and kept it really moving.
Awesome design, turned out really nice. You answered question I had at the end the end of the video. Thanks for the extra info.
Your skill is truly awe inspiring
This video is incredible!
Brian Oltrogge, your work is inspiring.
+Allan.Froehlich Thank you very much for your comment!
beautiful craftsmanship as always Brian and plz keep the videos coming
Video well done. I'll be using it for my materials and processing class to illustrate the sand casting technique. Your drawer pulls are very nice as well!
Beautiful job Brian and very well presented. Thanks.
Your work is sublime, take no notice of the smart ass comments, casting was always going to give the elegance needed!
Good job. Unbelievable quality!
Wow! Incredible craftsmanship to master all these different skills, keep up the awesome vids!
Very impressive. Thanks for allowing us to learn from you.