tag:blogger.com,1999:blog-54346344293699089042024-03-05T00:44:09.514-08:00Metal casting projectsThis blog is all about homemade foundry and metal casting projects, all made from recycled aluminum.FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comBlogger561500tag:blogger.com,1999:blog-5434634429369908904.post-79911251201111028572022-07-21T14:20:00.008-07:002022-07-21T14:51:23.290-07:00<h1 style="text-align: center;"><span style="font-size: medium;">Photogrammetry into 3D Print => Into a Solid Aluminum Metal Casting</span></h1><p>I have experimented the first time with lost PLA metal casting, I used as always recycled aluminum scrap for this project, I created in the past two 3D printings using photogrammetry method of two statues, since then I created various sizes of the statues 3d printings but always wanted to have them made from a more solid material such as metal.</p><p style="text-align: center;">You are welcome to view my<a href="https://youtu.be/dQoKOwS_8s0" target="_blank"><b> YouTube video of the metal casting</b></a> creation from start to finish ;-).
<iframe allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture" allowfullscreen="" frameborder="0" height="315" src="https://www.youtube.com/embed/dQoKOwS_8s0" title="YouTube video player" width="560"></iframe></p><h1 style="text-align: center;"><b><span style="font-size: medium;">Using Photogrammetry Method Transforming Images into a 3D Printed Object</span></b></h1><p>I started by using photogrammetry method taking around 80 images of each of the objects that I planned to turn into metal the main software I worked with was Autodesk ReCap Photo, once the stage of meshing and texturing was complete I did the final touches of removing additional backgrounds and cosmetic fixing's to the object surface. The next step was to upload the files to Ultimaker Cura 3d printing software and test some real 3d prints.</p><p>In the images you can see the stages of the Photogrammetry preparation, both for the owl statue and for the crying statue (AKA - The Legend of the Yogi Man - "Orang Malu").</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNhYhU1xXCOySQ1dmhXy-oBy6Q9hK-WvC6BK_G_7LsLLM3X1x0boTOa5n3cg66kMJToMxdcqkeGaRp_zcXwrpePh2A2eII2Pjpz7Cpo4T161g7qkb1TVWC6659RMpCdkAAe0enh9pJmW-53BGzhMnMw9FcVujc2VIXeVykMM0EawKyW7jgdGCAfVUkig/s5184/3D%20Print%20wooden%20statue.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2912" data-original-width="5184" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNhYhU1xXCOySQ1dmhXy-oBy6Q9hK-WvC6BK_G_7LsLLM3X1x0boTOa5n3cg66kMJToMxdcqkeGaRp_zcXwrpePh2A2eII2Pjpz7Cpo4T161g7qkb1TVWC6659RMpCdkAAe0enh9pJmW-53BGzhMnMw9FcVujc2VIXeVykMM0EawKyW7jgdGCAfVUkig/s320/3D%20Print%20wooden%20statue.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; 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text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjh1oUXC3BZR9l3bKVzFe-Wsu9IIO8qZzw0Aqi6jV27KjKirj2PuEM2KZBFCXDFic27iHBxrnvg32vEDumgSoqWwDZzr_Dxmf454_bk_Mt6ROxlKQzNlD7Y_aBf5U0lY68HRr_0spxG-7CL-W1qVAJuaDD15BMSBcVEBggjNM2GMyijyWwVZpWc-p_BWw/s1491/Photogrammetry%20to%203D%20print%208.png" style="margin-left: 1em; margin-right: 1em;"><img alt="Photogrammetry into 3D Print" border="0" data-original-height="791" data-original-width="1491" height="170" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjh1oUXC3BZR9l3bKVzFe-Wsu9IIO8qZzw0Aqi6jV27KjKirj2PuEM2KZBFCXDFic27iHBxrnvg32vEDumgSoqWwDZzr_Dxmf454_bk_Mt6ROxlKQzNlD7Y_aBf5U0lY68HRr_0spxG-7CL-W1qVAJuaDD15BMSBcVEBggjNM2GMyijyWwVZpWc-p_BWw/w320-h170/Photogrammetry%20to%203D%20print%208.png" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg77VLNCL2t1HsxW3EDZFC6I3lxdK5Q-FOY7daB9fWHYH7u951GoKcc87FKcjb8NVl9D9Qi9KcwfHDCFyRdG19TrB9vENNvOXgNir0f1wUM4EDNHVLO1oqa5jJ-kZgeoqCDjGkFuYZfZ413Is1Q1klJmFbdsPdFBzckwXfoRzJfVxsZr5jRhv1AIbz7cw/s1479/Photogrammetry%20to%203D%20print%209.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="793" data-original-width="1479" height="172" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg77VLNCL2t1HsxW3EDZFC6I3lxdK5Q-FOY7daB9fWHYH7u951GoKcc87FKcjb8NVl9D9Qi9KcwfHDCFyRdG19TrB9vENNvOXgNir0f1wUM4EDNHVLO1oqa5jJ-kZgeoqCDjGkFuYZfZ413Is1Q1klJmFbdsPdFBzckwXfoRzJfVxsZr5jRhv1AIbz7cw/s320/Photogrammetry%20to%203D%20print%209.png" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><blockquote style="border: none; margin: 0px 0px 0px 40px; padding: 0px;"><h1 style="clear: both; text-align: center;"><b><span style="font-size: medium;">3D Printing of the 2 Statues for the Lost PLA Metal Casting</span></b></h1></blockquote>I decided to make an experiment with four hollow 3d printed patterns, x2 in 2mm shell thickness and x2 in 1mm shell thickness. I wanted to experiment if there will be any difference in the aluminum casting details and my assumption was correct where the two 2mm aluminum casting failed while the other two in 1mm turned out much more successful, both not perfect but looking great for the first lost PLA test. I also learned that with lost PLA casting its important to extend the 3D printing and add an additional 1cm base to the object as the PLA rise up once the molten aluminum is poured and in my casting I lost 1cm in height vs the original 3D printing.<div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGnbR-08xJ8DsatFYu9IJwLuJKCgLo3_lT1GrONjsN6TGc3iRqCdocEGGSItQh3JMIYr28NerzSABahkJ98lNequBxl1BRuwzYZQbRy3uIzT_ZomHHFkNkKBpjE0Qc9FzKqJEzqzu96xq3IOBtlQEmc2S-GMYvJBjCyR_zXofsccYXOh-c9Le_s5yjjQ/s1920/CURA%203D%20Printing%201.png" style="margin-left: 1em; margin-right: 1em;"><img alt="Photogrammetry into 3D Print" border="0" data-original-height="1005" data-original-width="1920" height="168" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGnbR-08xJ8DsatFYu9IJwLuJKCgLo3_lT1GrONjsN6TGc3iRqCdocEGGSItQh3JMIYr28NerzSABahkJ98lNequBxl1BRuwzYZQbRy3uIzT_ZomHHFkNkKBpjE0Qc9FzKqJEzqzu96xq3IOBtlQEmc2S-GMYvJBjCyR_zXofsccYXOh-c9Le_s5yjjQ/w320-h168/CURA%203D%20Printing%201.png" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7y3cmNkoar9q7hnhAfVkMBapTFog7anmzTa5piw5aQfvxPiOLOcQnNRFqEyBznU7pQKJzQI8YJTYvt7HnFJa1PJSVkSuK0WZPCPImWQ5Mg3wj6eQ2QcjUpIeXPPBcgas5kOM-9dFBLU9xFkXYmKkO5Eh260h4mzS2Fa4IjaP4NW0r5QDBq0W8h_ffIw/s1920/CURA%203D%20Printing%202.png" style="margin-left: 1em; margin-right: 1em;"><img alt="Photogrammetry into 3D Print" border="0" data-original-height="994" data-original-width="1920" height="166" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7y3cmNkoar9q7hnhAfVkMBapTFog7anmzTa5piw5aQfvxPiOLOcQnNRFqEyBznU7pQKJzQI8YJTYvt7HnFJa1PJSVkSuK0WZPCPImWQ5Mg3wj6eQ2QcjUpIeXPPBcgas5kOM-9dFBLU9xFkXYmKkO5Eh260h4mzS2Fa4IjaP4NW0r5QDBq0W8h_ffIw/w320-h166/CURA%203D%20Printing%202.png" width="320" /></a></div><h1 style="text-align: center;"><span style="font-size: medium;">Testing</span><span style="font-size: medium;"> x4 3D Printings for Aluminum Metal Casting</span></h1><div>I was not sure if the 1mm thickness printing would have turned-out without inner filament support but to my surprise it turned out very well, I have changed the setting in Cura for the thickness of the external shell and 0% infill for all of the four printings.</div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgZbaFbM-FvAt5EpoA5-lEysZqOWk-1akxHSbzskXx1wYfBet7eDkCfZYbkvZv5IMmUgBGM81Scgt2mksFNQNsxJtMtg-9jTPYlsxqTM-GATQ8aVFRvxLB_qdad-bgDMo3VW_mx_IvWHyxhKue7W4t_2o_5BSJQGhbYDn5MYpfzgdivBc06U5y0USptw/s1783/3D%20Print%201.png" style="margin-left: 1em; margin-right: 1em;"><img alt="3D Print" border="0" data-original-height="958" data-original-width="1783" height="172" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgZbaFbM-FvAt5EpoA5-lEysZqOWk-1akxHSbzskXx1wYfBet7eDkCfZYbkvZv5IMmUgBGM81Scgt2mksFNQNsxJtMtg-9jTPYlsxqTM-GATQ8aVFRvxLB_qdad-bgDMo3VW_mx_IvWHyxhKue7W4t_2o_5BSJQGhbYDn5MYpfzgdivBc06U5y0USptw/w320-h172/3D%20Print%201.png" width="320" /></a></div><br /><h2 style="clear: both; text-align: center;"><span style="font-size: medium;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYk7VcqwNgFB9l6m0UKZf8QfzO94Z8MwkfdzrjHPjGhHyS2u3FoeVGPoZDfNheF9bJAvcMGwSaAJqYXhH5VU2jZolh05aVUy15VP-v12L8gJA2FUQwY0W80K30eBmONQkuXJjFwPsDZv01y8oe7OTtyqXMZcGsFSgIjXny6urVKeMirS1zE80UV1jhOg/s1588/3D%20Print%202.png" style="margin-left: 1em; margin-right: 1em;"><img alt="3D Print" border="0" data-original-height="961" data-original-width="1588" height="194" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYk7VcqwNgFB9l6m0UKZf8QfzO94Z8MwkfdzrjHPjGhHyS2u3FoeVGPoZDfNheF9bJAvcMGwSaAJqYXhH5VU2jZolh05aVUy15VP-v12L8gJA2FUQwY0W80K30eBmONQkuXJjFwPsDZv01y8oe7OTtyqXMZcGsFSgIjXny6urVKeMirS1zE80UV1jhOg/w320-h194/3D%20Print%202.png" width="320" /></a><br /></span></h2><h1 style="clear: both; text-align: center;"><span style="font-size: medium;">Using Oil Bonded Sand for the 3D Print Metal Casting</span></h1><div><span style="font-size: medium;">I used my very old but still usable Petrobond (Oil bonded sand) and buried the four 3D printings in the sand, next I used my mini soldering torch to start the hole at the base where the molten aluminum was to be poured into, the idea was to try and remove some of the PLA hoping it would reduce some of the casting defects as the PLA floats up once the molten aluminum is poured into it.</span></div><div><span style="font-size: medium;"><br /></span></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlu9JMtDGLZfuHZN9kBqq4Rm4lv5G-yjUnSd85NNz2AsuU5Y7fbgLXyL4mpOWWlaTK6RNlg3NMJ3QAoFfL_9YecG_4d2l-KoUmjT8kh8VK1iTZ1XjVD5CSc6VEsbVE37W5D8J88mfpRZUvL2pCj9NEFlbV5RO6V1fDmVJBwcjoafoEqpusmWvX2Qszeg/s1804/PLA%20sand%20casting%201.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="975" data-original-width="1804" height="173" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlu9JMtDGLZfuHZN9kBqq4Rm4lv5G-yjUnSd85NNz2AsuU5Y7fbgLXyL4mpOWWlaTK6RNlg3NMJ3QAoFfL_9YecG_4d2l-KoUmjT8kh8VK1iTZ1XjVD5CSc6VEsbVE37W5D8J88mfpRZUvL2pCj9NEFlbV5RO6V1fDmVJBwcjoafoEqpusmWvX2Qszeg/s320/PLA%20sand%20casting%201.png" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiioFcjK2kxFvsycp3EK7wJMVCRnbqFrTmLj2jKYggWvlClw67qSbQcxvDl0Wvbv3f6gekviG_v572qd0TZ3ZREBBPgecoZQc5Un1E8cOyaPAnH5JMbGZxG-S3GthBmqt6xPIyZkIRwN-eXpSsLbfR_spSy7JXrnfnfLvN7C-o1E-NCO72UP0AkD3XDQ/s5184/PLA%20sand%20casting%202.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2912" data-original-width="5184" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiioFcjK2kxFvsycp3EK7wJMVCRnbqFrTmLj2jKYggWvlClw67qSbQcxvDl0Wvbv3f6gekviG_v572qd0TZ3ZREBBPgecoZQc5Un1E8cOyaPAnH5JMbGZxG-S3GthBmqt6xPIyZkIRwN-eXpSsLbfR_spSy7JXrnfnfLvN7C-o1E-NCO72UP0AkD3XDQ/s320/PLA%20sand%20casting%202.jpg" width="320" /></a></div><h1 style="text-align: center;"><span style="font-size: medium;">The Aluminum Metal Casting Experiment - Success and Failure</span></h1></div><div><span style="font-size: medium;">I used my good old furnace and melted some recycled scarp aluminum, after degassing and removing the impurities I have poured the molten aluminium into the four sand mould cavities. After it cooled down a bit I removed the fresh aluminum castings from the sand and was surprised that my assumption was correct and the 1mm in thickness 3D printing's turned out well while the 2mm thickness failed. In the images you can see the difference before the final aluminum cleanup and light polish.</span></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgd9pYf4eciypi34qmNF6eg1anWo92Q4zj_FV-sc1EwJRg_19LHqzw10gUcIn__OB44IpvaRR0HdghHYvdxODn2uks1EBNwJ17BOp5xxOn7RqkFGNCWN4EuCBDjIMai7SWmMvq5sapAaGp5_JziYKZ5MSe-J0hDzn90UefQv_V4k1FO14liwdk1PJjZxQ/s1781/3d%20Print%20into%20Aluminum%20metal%20casting%202.png" style="margin-left: 1em; margin-right: 1em;"><img alt="Aluminum metal casting" border="0" data-original-height="970" data-original-width="1781" height="174" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgd9pYf4eciypi34qmNF6eg1anWo92Q4zj_FV-sc1EwJRg_19LHqzw10gUcIn__OB44IpvaRR0HdghHYvdxODn2uks1EBNwJ17BOp5xxOn7RqkFGNCWN4EuCBDjIMai7SWmMvq5sapAaGp5_JziYKZ5MSe-J0hDzn90UefQv_V4k1FO14liwdk1PJjZxQ/w320-h174/3d%20Print%20into%20Aluminum%20metal%20casting%202.png" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjP5x2yHWTqa_FfXJm52wkCAVK6N0KgTV0EWM9F3Y4oWVpkpPNeEkO_eO9LGipIK47SwBoupT8yNSfGa4NM2O9B22aktkiV4-XfbP2xSSAVnkYhhLB-vMdh2f-qOCpcrmkMxHBLpRGYN2IOF67wC9nXsPiswrAyIR3JudsfgDMozawghp71eHgXpBDa0A/s1339/3d%20Print%20into%20Aluminum%20metal%20casting%203.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="709" data-original-width="1339" height="169" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjP5x2yHWTqa_FfXJm52wkCAVK6N0KgTV0EWM9F3Y4oWVpkpPNeEkO_eO9LGipIK47SwBoupT8yNSfGa4NM2O9B22aktkiV4-XfbP2xSSAVnkYhhLB-vMdh2f-qOCpcrmkMxHBLpRGYN2IOF67wC9nXsPiswrAyIR3JudsfgDMozawghp71eHgXpBDa0A/s320/3d%20Print%20into%20Aluminum%20metal%20casting%203.png" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjP_tKq3orKMqDM_OQlx_dUsV3TqMlCSi-DUOYO6oMVDjs734YQGQ3NKw2vKkZgFTItECMGdbLILr-OrUAXivkY2Tm4tRrf0erJXcBFfplbO-6Um8DBIg8f5O_W2Tmab2fWaDCS-FnMBiXBj-zHP3VOaPBzqmLg--fQqYOK3wZ6CumMcJnoxRt6QQhmpA/s5184/3d%20Print%20into%20Aluminum%20metal%20casting%204.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2912" data-original-width="5184" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjP_tKq3orKMqDM_OQlx_dUsV3TqMlCSi-DUOYO6oMVDjs734YQGQ3NKw2vKkZgFTItECMGdbLILr-OrUAXivkY2Tm4tRrf0erJXcBFfplbO-6Um8DBIg8f5O_W2Tmab2fWaDCS-FnMBiXBj-zHP3VOaPBzqmLg--fQqYOK3wZ6CumMcJnoxRt6QQhmpA/s320/3d%20Print%20into%20Aluminum%20metal%20casting%204.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1dvQpxnBb-qNpGn9j1mbaxdUer_HjWYzR1ngrZ1VhLDSNPC7XxTFGLxwOv61K9eGz0wsA9ZbciJNBFyN1ZRbbZF_a9hJ7FhY1Yea36XaYB0DjkjhfK8sd9t_pJEfXSd-iGslk9-uVOPIOzQhdxlv1Ghj08jwrmmt3mSIHc0pkQ5yDviYeYdX7w1nOgA/s1351/3d%20Print%20into%20Aluminum%20metal%20casting%206.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="703" data-original-width="1351" height="167" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1dvQpxnBb-qNpGn9j1mbaxdUer_HjWYzR1ngrZ1VhLDSNPC7XxTFGLxwOv61K9eGz0wsA9ZbciJNBFyN1ZRbbZF_a9hJ7FhY1Yea36XaYB0DjkjhfK8sd9t_pJEfXSd-iGslk9-uVOPIOzQhdxlv1Ghj08jwrmmt3mSIHc0pkQ5yDviYeYdX7w1nOgA/s320/3d%20Print%20into%20Aluminum%20metal%20casting%206.png" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgI4Xtly6K9hziQdX9dva7tPzUkniHGQsiVD1RrtIfAovQxENc7OWF6NBQmae3xvUPf1xEnOKcpKTTNw9PvEg0eNjOC4TVFxKuqHgl7__1_Dp3cwpeOCRl9ebyT9-yH1w4Qf7w5NoeLzC_metetdbt0lGfGZvqqPiYfa9wtoZJMRoREDSUUVdjfN9PX8g/s955/3d%20Print%20into%20Aluminum%20metal%20casting%209.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="516" data-original-width="955" height="173" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgI4Xtly6K9hziQdX9dva7tPzUkniHGQsiVD1RrtIfAovQxENc7OWF6NBQmae3xvUPf1xEnOKcpKTTNw9PvEg0eNjOC4TVFxKuqHgl7__1_Dp3cwpeOCRl9ebyT9-yH1w4Qf7w5NoeLzC_metetdbt0lGfGZvqqPiYfa9wtoZJMRoREDSUUVdjfN9PX8g/s320/3d%20Print%20into%20Aluminum%20metal%20casting%209.png" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhi2oj_ywkMRen66eSq24dGVNXPvMi3NjWYdMfkojnvUQAeXLaiNO3URKmGaBo3iOr_0IE7LqGbDTnpRdhlkXV0XMumiHVWuwzJt3aWfVqQ7371GuD6wU89v779iCNnPw0ti6CWYmTcRLny5WNlVd9R1lqP8UsQz2kUXz9fZKz2_EM5jxk1R-hJ6Xcp6g/s778/3d%20Print%20into%20Aluminum%20metal%20casting%2010.png" style="margin-left: 1em; margin-right: 1em;"><img alt="aluminum metal casting" border="0" data-original-height="517" data-original-width="778" height="213" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhi2oj_ywkMRen66eSq24dGVNXPvMi3NjWYdMfkojnvUQAeXLaiNO3URKmGaBo3iOr_0IE7LqGbDTnpRdhlkXV0XMumiHVWuwzJt3aWfVqQ7371GuD6wU89v779iCNnPw0ti6CWYmTcRLny5WNlVd9R1lqP8UsQz2kUXz9fZKz2_EM5jxk1R-hJ6Xcp6g/w320-h213/3d%20Print%20into%20Aluminum%20metal%20casting%2010.png" width="320" /></a></div><h1 style="text-align: center;"><span style="font-size: medium;"> Aluminum Casting Clean Up and Light Polish</span></h1><p>I use a saber saw to cut off the extra aluminum base and an angle grinder to clean and flat the base. After I gave the aluminum casting some light clean up and buffing.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNrkW4tpfmd9U2R34eHLaPvFrCzmcNu0SNxMYf8Am8RPYtNKADHLGffcJn31Bur0BD_vBV1hfvGcrLOlNOpMYWb7f3Pk70lVRuDCKEOXwfqSB5017K5ENIP3L2x9ct78cf-6jRjxUtf08MJ7mgJMBNYWHOSH1vSUbMdo4v6S7DByPKx0I92HSZBhAcYg/s1792/3d%20Print%20into%20Aluminum%20metal%20casting%2011.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="975" data-original-width="1792" height="174" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNrkW4tpfmd9U2R34eHLaPvFrCzmcNu0SNxMYf8Am8RPYtNKADHLGffcJn31Bur0BD_vBV1hfvGcrLOlNOpMYWb7f3Pk70lVRuDCKEOXwfqSB5017K5ENIP3L2x9ct78cf-6jRjxUtf08MJ7mgJMBNYWHOSH1vSUbMdo4v6S7DByPKx0I92HSZBhAcYg/s320/3d%20Print%20into%20Aluminum%20metal%20casting%2011.png" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgN8w-SlL7bhZHH4TPrI6hLorDJUQ6Z1D8zHpY6fJO0IxaGfikhey5nNtwsvxU79m3v7DyRT0Y5hX9f8zJwrQX_LnuX5CnuHqfENxFylferlaDyByuloYRYi0XY5-pzmTvlfQ2X_zwQnOKuxZeqKFBFXuXLo-1lkPIVXsbDqu2KZn5wl-XBlx9I-PIzIg/s961/3d%20Print%20into%20Aluminum%20metal%20casting%2012.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="520" data-original-width="961" height="173" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgN8w-SlL7bhZHH4TPrI6hLorDJUQ6Z1D8zHpY6fJO0IxaGfikhey5nNtwsvxU79m3v7DyRT0Y5hX9f8zJwrQX_LnuX5CnuHqfENxFylferlaDyByuloYRYi0XY5-pzmTvlfQ2X_zwQnOKuxZeqKFBFXuXLo-1lkPIVXsbDqu2KZn5wl-XBlx9I-PIzIg/s320/3d%20Print%20into%20Aluminum%20metal%20casting%2012.png" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjx_0prUQt-QmzvZE3lhNFAP1WQONyRm3x6nOCi15QFyMPLr1Fnrz8DdQzX7VL4BgskE5EjMJEmGC2HtXgVj7biJDRJ1Vv_otoeQv1F9i2GWQjUO2yJ0e4m_OUEbChjD6tf6QsWb_E1K5r8CLAPvo-Ym0M1RjsxplsH8Jtxbpb-HpvuKrQ8c-v2Vg7i4w/s948/3d%20Print%20into%20Aluminum%20metal%20casting%2013.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="511" data-original-width="948" height="172" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjx_0prUQt-QmzvZE3lhNFAP1WQONyRm3x6nOCi15QFyMPLr1Fnrz8DdQzX7VL4BgskE5EjMJEmGC2HtXgVj7biJDRJ1Vv_otoeQv1F9i2GWQjUO2yJ0e4m_OUEbChjD6tf6QsWb_E1K5r8CLAPvo-Ym0M1RjsxplsH8Jtxbpb-HpvuKrQ8c-v2Vg7i4w/s320/3d%20Print%20into%20Aluminum%20metal%20casting%2013.png" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjP77HGIwIN5pWMwbUrs1wGnQVQGr5yhWjvBvxqCk4bGVcHavlQ-rB_3uQV4d26O5WwXT4c-U_tz4FWRaUiKd6nn79EG2idRH5zbrD7YTae4P9Nwj4FUF6iYl1CLUP5Hmz_xfXRL-_4fx-bQZItkhr_4-nd-pNjz-qi8y6ZkhqAU9xCayv43nzdJbnpJw/s931/3d%20Print%20into%20Aluminum%20metal%20casting%2014.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="502" data-original-width="931" height="173" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjP77HGIwIN5pWMwbUrs1wGnQVQGr5yhWjvBvxqCk4bGVcHavlQ-rB_3uQV4d26O5WwXT4c-U_tz4FWRaUiKd6nn79EG2idRH5zbrD7YTae4P9Nwj4FUF6iYl1CLUP5Hmz_xfXRL-_4fx-bQZItkhr_4-nd-pNjz-qi8y6ZkhqAU9xCayv43nzdJbnpJw/s320/3d%20Print%20into%20Aluminum%20metal%20casting%2014.png" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWdpn5uplV8Ip6oOOUDVrd6jEP_NI3L0c_F5Egcb5lgY0_sYNu2_UJYOuj1dTUhtQIjiL4KgFQraooRuO0mmlh0Y1wZe9wZOSavO5jVuLLXuX9J_L-HCsNegP1aqgTgRz8sSAYd7xmWUq-hUJYeU6jS8rStzJX7m_1Hb8uR934u9N9bxdWCtSiyKksnw/s1549/3d%20Print%20into%20Aluminum%20metal%20casting%2015.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="928" data-original-width="1549" height="192" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWdpn5uplV8Ip6oOOUDVrd6jEP_NI3L0c_F5Egcb5lgY0_sYNu2_UJYOuj1dTUhtQIjiL4KgFQraooRuO0mmlh0Y1wZe9wZOSavO5jVuLLXuX9J_L-HCsNegP1aqgTgRz8sSAYd7xmWUq-hUJYeU6jS8rStzJX7m_1Hb8uR934u9N9bxdWCtSiyKksnw/s320/3d%20Print%20into%20Aluminum%20metal%20casting%2015.png" width="320" /></a></div><h1 style="text-align: center;"><span style="font-size: medium;">The 3D Printing and the Final Aluminum Metal Casting</span></h1><p>The final project result below, I will probably try at some point in the future to create a larger metal casting of a 3D printing Yogi Man ;-) and add additional base to fix/compensate of the couple of mm's missing at the bottom of the metal casting.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvbtADop68jc76O8Ywg5E-5swlv_QM2iXPsVo9yz3RkQ_Z3P1GR-aKWghRTG6ZUMwYSwxOg6LbRIboj-pD0zzlIbfWWBfOdYF0K-g0msg1r2HnIVjayhfdCJ9zBCTuCPbwoy-S_--HHw9-PxGWC8V5_euet56MkqwIB0SR-cnDQwi-Opk2EMhAYQ7-MQ/s5184/3D%20print%20into%20Aluminum%20Metal%20Casting%2013.jpg" style="margin-left: 1em; margin-right: 1em;"><img alt="3D print and aluminum metal casting" border="0" data-original-height="2912" data-original-width="5184" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvbtADop68jc76O8Ywg5E-5swlv_QM2iXPsVo9yz3RkQ_Z3P1GR-aKWghRTG6ZUMwYSwxOg6LbRIboj-pD0zzlIbfWWBfOdYF0K-g0msg1r2HnIVjayhfdCJ9zBCTuCPbwoy-S_--HHw9-PxGWC8V5_euet56MkqwIB0SR-cnDQwi-Opk2EMhAYQ7-MQ/w400-h225/3D%20print%20into%20Aluminum%20Metal%20Casting%2013.jpg" width="400" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLzjsCLTaiomALAcae3YHHgFQ59HJ1jxwchekj5-njHCHUzBjROBZOXRuofXtI_Bah1-R3RhPBvNtc4dY15LsjretMgZhTibcbb3HogxPti-XblEalHpyGJaB33BDE96WgmXfrgM_FEdj2KbE5GPQFiuJCh3YvbHT58ZHihOxCEgt0TOTCyg7B_Gf96w/s4000/3D%20print%20into%20Aluminum%20Metal%20Casting%2016.png" style="margin-left: 1em; margin-right: 1em;"><img alt="3D print and aluminum metal casting" border="0" data-original-height="3000" data-original-width="4000" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLzjsCLTaiomALAcae3YHHgFQ59HJ1jxwchekj5-njHCHUzBjROBZOXRuofXtI_Bah1-R3RhPBvNtc4dY15LsjretMgZhTibcbb3HogxPti-XblEalHpyGJaB33BDE96WgmXfrgM_FEdj2KbE5GPQFiuJCh3YvbHT58ZHihOxCEgt0TOTCyg7B_Gf96w/w640-h480/3D%20print%20into%20Aluminum%20Metal%20Casting%2016.png" width="640" /></a></div><p><br /></p><p><br /></p></div>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-85909522501037924342021-08-14T14:39:00.016-07:002021-08-28T14:31:59.508-07:00<h2 style="text-align: left;"><b><u><a href="https://www.flamingfurnace.com/2021/08/cheap-axe-into-viking-style-axe-i-just.html" target="_blank"> Turning A Cheap Axe into a Viking Style Axe</a></u></b></h2><p>I just posted a new video where I took an old axe and turned it into a cool looking Viking axe style, I have used first time metal etching in this project, and sand casting to create the new solid aluminum handle. As always all the aluminum used is from recycled old parts, Feel free to check my YouTube video below with all the steps and don't forget to tap on like, subscribe or just leave a comment ;-).</p>
<div style="text-align: center;"><iframe allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture" allowfullscreen="" frameborder="0" height="315" src="https://www.youtube.com/embed/PMw5DP7ZSD0" title="YouTube video player" width="560"></iframe></div><div style="text-align: center;"><br /></div><div style="text-align: left;">The first step was to create the new Viking axe design, I used basic material's to create the shape such as WD40 metal can, duct tape roll and T-Pex pen pen to mark the lines. I have also removed the old handle easily by drilling the axe head. </div><div style="text-align: center;"><br /></div><div style="text-align: left;"><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhH9-rnBmhKfcm3FkxghlnEI0Gsfjb3RbQ-lA3RtaCKU2F_X6EthwEhVxE9SF2-0B6RN6Q2HbyA5GZUFcvy881Vv7cBZ-bMEwhB5g2pSJU79lKyis-98lMfqAOQNlg2ODc6NH5I8QzAb_Ns/" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="540" data-original-width="540" height="367" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhH9-rnBmhKfcm3FkxghlnEI0Gsfjb3RbQ-lA3RtaCKU2F_X6EthwEhVxE9SF2-0B6RN6Q2HbyA5GZUFcvy881Vv7cBZ-bMEwhB5g2pSJU79lKyis-98lMfqAOQNlg2ODc6NH5I8QzAb_Ns/w367-h367/DIY+Turning+A+Cheap+Axe+Into+A+Viking+Style+Axe.png" width="367" /></a></div><div class="separator" style="clear: both; text-align: center;"><b>Step 1: </b>designing the Viking axe shape</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgD5717UPX2KzM2iP-ZpkAlxonQBZO5qZbYgWjFW71C0XdJkmfdgUA6QKsGtX-y8_JkafkagvT4qzdAQfwnYxjcaGipW8EKVR4xcA4V1fWxtxnv4MkkVPW0IdBoB2XpLxi-tHekDwGtWGRC/" style="margin-left: 1em; margin-right: 1em;"><img alt="Making a Viking axe style from a cheap axe/hatchet" data-original-height="2912" data-original-width="5184" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgD5717UPX2KzM2iP-ZpkAlxonQBZO5qZbYgWjFW71C0XdJkmfdgUA6QKsGtX-y8_JkafkagvT4qzdAQfwnYxjcaGipW8EKVR4xcA4V1fWxtxnv4MkkVPW0IdBoB2XpLxi-tHekDwGtWGRC/w400-h225/DIY+Viking+axe+design.JPG" width="400" /></a></div><div class="separator" style="clear: both; text-align: left;"><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><br /></div><b>Step 2:</b> removing the old cheap handle<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihHhOTT-YK4RCHnA9zlseM-KaqFQEiYg8LRzc5NVE1WSOJfNDGYwnUxp63bqsMNo2j1UzkotnC-NpD_VfJKOSbaaK2IBNEyuEMyEMzcb4383gZ9BoVOevXlNTRTOJj6J8VykfOtxnufLGk/" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="2912" data-original-width="5184" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihHhOTT-YK4RCHnA9zlseM-KaqFQEiYg8LRzc5NVE1WSOJfNDGYwnUxp63bqsMNo2j1UzkotnC-NpD_VfJKOSbaaK2IBNEyuEMyEMzcb4383gZ9BoVOevXlNTRTOJj6J8VykfOtxnufLGk/w400-h225/Removing+axe+handle.JPG" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><b>Step 3: </b>using and angle grinder cutting the shape of the Viking axe</div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcBYBrwiIwUfzuXrFQa1_iuhww7mHfH-ISp0-ACWFuNXpeUY8YPYL1UfNe_1At6nPbRegnXyBf_I73bjxTInBXxpyIwMWjBBURm0-gFYjtEyIXQJ9MrA8A1IpughKXSsbxqb1wmGOxHViA/" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="2912" data-original-width="5184" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcBYBrwiIwUfzuXrFQa1_iuhww7mHfH-ISp0-ACWFuNXpeUY8YPYL1UfNe_1At6nPbRegnXyBf_I73bjxTInBXxpyIwMWjBBURm0-gFYjtEyIXQJ9MrA8A1IpughKXSsbxqb1wmGOxHViA/w400-h225/Designing+and+cutting+a+Viking+axe.JPG" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;">Once the shape was cut with an angle grinder I did some sanding with a flap disc and sand paper</div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8JWbL2O1_VtckIfPYKYFuS9e3EzHTL-v073MWhlNPkeKUFV_xOcm4jEhAttK7veV75OG_6Zp_z5ZFEEKFx7koWU-96ajK81XX3n6960-PyUlWL1exwAcF7VwbYmL6xmYhVxuEyUilgIGY/" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="2912" data-original-width="5184" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8JWbL2O1_VtckIfPYKYFuS9e3EzHTL-v073MWhlNPkeKUFV_xOcm4jEhAttK7veV75OG_6Zp_z5ZFEEKFx7koWU-96ajK81XX3n6960-PyUlWL1exwAcF7VwbYmL6xmYhVxuEyUilgIGY/w400-h225/DIY+shaping+a+Viking+axe+head.JPG" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><b>Step 4:</b> Oil heat treatment of the Viking axe head, for extra strength and durability<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjItY1MbNSt49lVvkmBSabzzE-YBUxeg4eX8hoc4YhOZllLsBnHhOiCnnmHrsRB4SRHu4gJli24ikLIoLPO67ObSG26Sa9DInT31-oze2Jpf7C2Uwh2JrWSmpsBd5ZT97-jweei-7l57DV_/" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="2912" data-original-width="5184" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjItY1MbNSt49lVvkmBSabzzE-YBUxeg4eX8hoc4YhOZllLsBnHhOiCnnmHrsRB4SRHu4gJli24ikLIoLPO67ObSG26Sa9DInT31-oze2Jpf7C2Uwh2JrWSmpsBd5ZT97-jweei-7l57DV_/w400-h225/Viking+axe+heat+treatment.JPG" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><b>Step 5: </b>creating the sand mold and casting the aluminum into a sand mould with the Viking axe head inside. The aluminum casting turned out very well just required some light cleanup ;-).<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBzjtW9wXwjaHhw2v96ulTwsokVGsLwLby2r9GrPMzAftRaApnTEWLhoEDjhfli3n8OhUaBVgltkT2K2ihP7NdqOnvr-yOveVg838Smr1ULl8-4JQCwk1a-oB6ac_q7bfc-lMotw7OKSFb/" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="2912" data-original-width="5184" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBzjtW9wXwjaHhw2v96ulTwsokVGsLwLby2r9GrPMzAftRaApnTEWLhoEDjhfli3n8OhUaBVgltkT2K2ihP7NdqOnvr-yOveVg838Smr1ULl8-4JQCwk1a-oB6ac_q7bfc-lMotw7OKSFb/w400-h225/Aluminum+Viking+axe+sand+casting.JPG" width="400" /></a></div></div><div class="separator" style="clear: both; text-align: center;"><br /><b> Step 6: </b>To create extra support of the axe head to the new casted aluminum handle I used my bench drill, drilling two holes and welding x2 metal pins for extra strength, then cleaned the surface with angle grinder and you could never guess there are 2 pins welded<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg14yfyTrWk-MrJz6vDZL3-xy6rHh9_dX96B5VIMvXg5id7b4wjQagPIZJ8q0YLqT9Ls6dJHQaZQAmf0qRsUXWI1nL9-yxhGbH5kLxD19kbeNfp29afwJHPeDgE3ij-5NssFEiNUtWHrwtS/" style="margin-left: 1em; margin-right: 1em;"><img alt="Making a Viking axe style from a cheap axe/hatchet and aluminum handle casting" data-original-height="2912" data-original-width="5184" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg14yfyTrWk-MrJz6vDZL3-xy6rHh9_dX96B5VIMvXg5id7b4wjQagPIZJ8q0YLqT9Ls6dJHQaZQAmf0qRsUXWI1nL9-yxhGbH5kLxD19kbeNfp29afwJHPeDgE3ij-5NssFEiNUtWHrwtS/w400-h225/Viking+axe+welding+with+aluminum+sand+casting+of+the+handle.JPG" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;">After the metal pins welding and cleanup on both sides</div></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioa94AWknO8_mlGnpod2CF_bksnzJlGlOl6MMWsvs_NChiX1tRD4kH1VSdpASCHTtAHFcxK3-8gbdltA2WQPaJE8k51cGDw2qP4Jm3esTGNaDwHYGffVRYZTt5ir5hw-jwnrNNZIu3jao7/" style="margin-left: 1em; margin-right: 1em;"><img alt="Making a Viking axe style from a cheap axe/hatchet" data-original-height="2912" data-original-width="5184" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioa94AWknO8_mlGnpod2CF_bksnzJlGlOl6MMWsvs_NChiX1tRD4kH1VSdpASCHTtAHFcxK3-8gbdltA2WQPaJE8k51cGDw2qP4Jm3esTGNaDwHYGffVRYZTt5ir5hw-jwnrNNZIu3jao7/w400-h225/IMG_0319.JPG" width="400" /></a></div><br /><b>Step 7: </b>I used metal etching with a 12V car battery charger, salt and lemon to create two words in <a href="https://en.wikipedia.org/wiki/Paleo-Hebrew_alphabet" target="_blank">(ancient Paleo (1200BC) Wiki)</a> - one words refers to "Good" and the other word "Evil", I thought its symbolic as an axe can be used as a weapon in times of war and other times just for survival/camping to chop wood. I used electrical tape and <span style="background-color: white; color: #333333; font-family: Arial, Helvetica, Verdana, Tahoma, sans-serif; font-size: 15px; text-align: start;">Tipp-ex pen</span> to create the words and shapes across the Viking axe head.</div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcKOkKHOFAJcom5540FXvx4geqMluodznANIoeFNhG9dqXExmfLf0zeqX2swhLYw8Mx-H5ilkIqA-B_kU1dPe4wJebwNIhdac7tu_4v7NiWgdkjZqGFPC0K6oDZLq6ZlmtkVB5AWX7MWWT/" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="2048" data-original-width="1449" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcKOkKHOFAJcom5540FXvx4geqMluodznANIoeFNhG9dqXExmfLf0zeqX2swhLYw8Mx-H5ilkIqA-B_kU1dPe4wJebwNIhdac7tu_4v7NiWgdkjZqGFPC0K6oDZLq6ZlmtkVB5AWX7MWWT/w283-h400/Paelo+1200BC+metal+casting+aluminum+Viking+axe.jpg" width="283" /></a></div><br /></div><div class="separator" style="clear: both; text-align: center;">Metal etching with basic materials</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh07uKvjq8npTLbhzaU8R04zdYAmb5WprzlsGJkIkr30D_IVqXfv3zu2-IILltSptavJzAjIBa6c85IPpMeYYh8_8hukAAH1t6SN6Fu4r1i91pvDnzTXaN2cDyifVhltw4n7z7s7pdqRql3/" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="3888" data-original-width="5184" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh07uKvjq8npTLbhzaU8R04zdYAmb5WprzlsGJkIkr30D_IVqXfv3zu2-IILltSptavJzAjIBa6c85IPpMeYYh8_8hukAAH1t6SN6Fu4r1i91pvDnzTXaN2cDyifVhltw4n7z7s7pdqRql3/w400-h300/Metal+etching+Viking+axe.JPG" width="400" /><br /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div>First look after short etching, this was just my first test next time I might do deeper metal etching</div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1oQxtwnRic7W4P9mgIza7oaM6Rsne-hDqKITsdLeIdAzlXfLJhr4DU5wU2EpJmCH7r8L961E2b0yDpPRTo4SPuQACiW-ARP2hY_8U6tVybDqwY0IuPKQ55z8JeJvZ-44_jRWDnlTt_-sb/" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="3888" data-original-width="5184" height="301" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1oQxtwnRic7W4P9mgIza7oaM6Rsne-hDqKITsdLeIdAzlXfLJhr4DU5wU2EpJmCH7r8L961E2b0yDpPRTo4SPuQACiW-ARP2hY_8U6tVybDqwY0IuPKQ55z8JeJvZ-44_jRWDnlTt_-sb/w401-h301/Matel+etching+axe+head.JPG" width="401" /></a></div></div><div class="separator" style="clear: both; text-align: center;"><br /></div><b>Step 8:</b> After a bit of aluminum polish I used a Paracord to wrap around the axe handle (simple west country whipping) and lastly sharpened the axe blade a bit, and that's it turned out very cool ;-).</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhClVlhNT6ML7EvqWjc-Zz_sBxv3E-r5oYXfszSI3bxcTOP8ktaVRC02VfynqSmX6SXfqS3b-OZITxiio5rIGXOnKORIEhV9YPt09916UONvM0o5wNREs8ua_ixQCSFLgVtZW3GjBt0334Q/" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="3888" data-original-width="5184" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhClVlhNT6ML7EvqWjc-Zz_sBxv3E-r5oYXfszSI3bxcTOP8ktaVRC02VfynqSmX6SXfqS3b-OZITxiio5rIGXOnKORIEhV9YPt09916UONvM0o5wNREs8ua_ixQCSFLgVtZW3GjBt0334Q/w400-h300/Aluminum+casting+Viking+axe+handle+with+Paracord+2.JPG" width="400" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgF8Jg4DbnyEgEUetaR3PnZAn9gO0SXNViY4vBPVrlI5uOdQDf1DI_IXUYBdd-lsVJ5YEEtwzfYlUL23xfhkA8Gmbd1xWVAIItw8xx7hondKVKBWb4W_y8gytUPkEUxBk-xbnDgw_y9Qaeo/" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="3888" data-original-width="5184" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgF8Jg4DbnyEgEUetaR3PnZAn9gO0SXNViY4vBPVrlI5uOdQDf1DI_IXUYBdd-lsVJ5YEEtwzfYlUL23xfhkA8Gmbd1xWVAIItw8xx7hondKVKBWb4W_y8gytUPkEUxBk-xbnDgw_y9Qaeo/w400-h300/Aluminum+casting+Viking+axe+handle+with+Paracord+1.JPG" width="400" /><br /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div>Ready to chop some wood<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg91GaMEMzi9uAuUugIKHwvF54_4TtEGGnnCjoJHXMYPjz8Hner5ZndtoVaowO39PhyQk0oK-qv7YKUlbpV3SoTEjsy3HV0w5D_RK0lmqaaS3OLiM82Q1LYnI78PogqLGOcg_ckx5GBttJk/" style="margin-left: 1em; margin-right: 1em;"><img data-original-height="2048" data-original-width="1536" height="493" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg91GaMEMzi9uAuUugIKHwvF54_4TtEGGnnCjoJHXMYPjz8Hner5ZndtoVaowO39PhyQk0oK-qv7YKUlbpV3SoTEjsy3HV0w5D_RK0lmqaaS3OLiM82Q1LYnI78PogqLGOcg_ckx5GBttJk/w370-h493/20210814_192549.jpg" title="Viking axe made from a cheap hatchet" width="370" /></a></div></div></div></div><div class="separator" style="clear: both; text-align: center;"><br /></div></div><br /><br /></div><br /><br /></div>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-42444667308894272592020-08-18T18:02:00.008-07:002020-08-22T07:14:56.463-07:00Electrolysis Rust Removal Tutorial<span style="font-family: arial;">In this Electrolysis Rust Removal Tutorial I used an old rusty adjustable spanner just to demonstrate how efficient this method is, absolutely fantastic for home DIY use, work place or any restoration projects. The setting is very basic and takes 5 minutes at a very low cost once you have an old battery charger lying around or even a spare mobile charger. Most important is not to get confused with the Positive (+) and Negative (-) connections ;-). Feel free to check my YouTube channel, Like, Subscribe or drop me a comment below my video.</span><div><span style="font-family: arial;"><br /></span><div><div style="text-align: center;"><span style="font-family: verdana;"><i><b><span style="color: red;">Feel free to check</span><span style="color: #2b00fe;"> </span><a href="https://www.youtube.com/channel/UC9w9GotC04y1G-U4itByJUA?view_as=subscriber" style="color: #2b00fe;">my other Rust Removal videos</a><span style="color: red;"> on my YouTube channel</span></b></i></span></div><p></p>
<div style="text-align: center;"><iframe allow="accelerometer; autoplay; encrypted-media; gyroscope; picture-in-picture" allowfullscreen="" frameborder="0" height="315" src="https://www.youtube.com/embed/09ck7R9zvUw" width="560"></iframe></div><div class="separator" style="clear: both; text-align: justify;"><span style="font-family: arial;"><br /></span></div><span style="font-family: arial;"><div style="text-align: left;">Below you can see the before and after results after 1 night of electrolysis de-rusting, the duration depends on the level of rust, for light rust a few hours is more then enough, for heavy rust over night or more might be more suitable. After the electrolysis is done a bath of vinegar is recommended for the de-rusted part, makes it easier to clean all the electrolysis left over residue. The adjustable spanner below was covered with rust over 4 years.</div></span><div style="text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg03OmFB7v1PIm0bU8U8q_xueMzUp7mOLaT3KDYi_pdtK3HA6lTFfq77k_JWXl34qtudF1o_zCaWYKjTzZnFC5yoHTz3rCNBZieAZ3tqH7L-a7rnjtqQY65CaUDoRJ3X7UIn0AfUI0GNx8r/s960/Electrolysis+Rust+Removal+before.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="540" data-original-width="960" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg03OmFB7v1PIm0bU8U8q_xueMzUp7mOLaT3KDYi_pdtK3HA6lTFfq77k_JWXl34qtudF1o_zCaWYKjTzZnFC5yoHTz3rCNBZieAZ3tqH7L-a7rnjtqQY65CaUDoRJ3X7UIn0AfUI0GNx8r/s640/Electrolysis+Rust+Removal+before.png" width="640" /></a></div><p style="text-align: center;"></p><div style="text-align: left;"><br /></div><span style="font-family: arial;"><div style="text-align: left;">After the de-rusting process is complete I would recommend to cover the part with some lubricating oil, alternatively spray paint it after the cleaning as it will oxidize very quickly if not treated.</div></span><p></p><div class="separator" style="clear: both; text-align: center;"><br /></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtrDF9ny9ZElz0X4rpL-ypxhyphenhyphenjMktw1-OuctJDQAnUp8-O4Lt9i6MF1xp8MgHTjN8riV3sLYKdT5pA-DTZaqgsJ4gbKPLYAcUoqNaYgCRpCG-3ANsWtxSQ1vGwmacnJngcSeLvI6DIUqXo/s960/Electrolysis+Rust+Removal+after.png" style="margin-left: auto; margin-right: auto; text-align: center;"><img border="0" data-original-height="540" data-original-width="960" height="360" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtrDF9ny9ZElz0X4rpL-ypxhyphenhyphenjMktw1-OuctJDQAnUp8-O4Lt9i6MF1xp8MgHTjN8riV3sLYKdT5pA-DTZaqgsJ4gbKPLYAcUoqNaYgCRpCG-3ANsWtxSQ1vGwmacnJngcSeLvI6DIUqXo/w640-h360/Electrolysis+Rust+Removal+after.png" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><br /></td></tr></tbody></table><br /></div></div>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-27966609231627417022019-12-31T14:51:00.001-08:002019-12-31T14:51:34.753-08:003D Printing addition to this blog 💥Wow its been over a year since I last posted on my blog, this year was super busy with my full time job, finishing my last year of psychology in collage and crazy busy family life, time just flies. So I didn't have much time for metal casting this year but I did find some extension to this hobby that I will probably incorporate into my future metal casting. Around Jan' this year I purchased my first 3D printing machine of Creality CR-10S,<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKNSnJLW6hQvbwde0dlpxnoyU4xF66MbxAk4310WW06xrhJeCFd23GRL8Aqwl_EaChiD8DaIm0dj9qRR3arWBi1dOQiIETy91CvEGfgFLP0JFh7_aQoKY6iIZ8jXLaKPreEvWcMgH2VHcO/s1600/Creality+CR10S.PNG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" data-original-height="696" data-original-width="782" height="177" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKNSnJLW6hQvbwde0dlpxnoyU4xF66MbxAk4310WW06xrhJeCFd23GRL8Aqwl_EaChiD8DaIm0dj9qRR3arWBi1dOQiIETy91CvEGfgFLP0JFh7_aQoKY6iIZ8jXLaKPreEvWcMgH2VHcO/s200/Creality+CR10S.PNG" width="200" /></a></div>
I did some printing this year and I would like to share with you some of the more interesting ones. Majority of my 3D printings I downloaded from <a href="https://www.thingiverse.com/" target="_blank">Thingiverse</a> web site, remixing some and others I have created using the fantastic <a href="https://www.tinkercad.com/" target="_blank">Tinkercad</a> easy to use app for 3D design, electronics and coding. So long story short I am far from being an expert in relation to 3D Printing but I know more then what I knew last year ;-).<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXHcddjva5zdqqBQAhypkZ6_ucpBXaPxiGycSuvScPz5SgqnB1Yd6RAQPN9DRcEYc8EYPBL5ZzeEws8IEKZ3oFek6QFuv2tNrrZ-QyGS7s1oOI3fUovfxE6CMR9w_mdA2FBQLCxZCEVx6s/s1600/Star+wars+1.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" data-original-height="985" data-original-width="1600" height="196" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXHcddjva5zdqqBQAhypkZ6_ucpBXaPxiGycSuvScPz5SgqnB1Yd6RAQPN9DRcEYc8EYPBL5ZzeEws8IEKZ3oFek6QFuv2tNrrZ-QyGS7s1oOI3fUovfxE6CMR9w_mdA2FBQLCxZCEVx6s/s320/Star+wars+1.jpg" width="320" /></a></div>
My most recent 3D Printing was of a Star Wars Rebel Escort ship (Remix) from the creator <a href="https://www.thingiverse.com/thing:2882980" target="_blank">Colin 300zxcolin</a> full credit goes to him for sharing the files. I felt ready to try a larger size print and it turned out awesome, I used white and grey filament and will probably spray paint it at some point in the future. On the left you can see the finished print. As a huge Star Wars and Star Trek fan I did some previous space ship prints but nothing compares to the scale of this one, I have replaced and added front swiveling cannons, swiveling missile launchers, turret tower guns (borrowed from the empire death star ㋡), Side missiles, round turrets, internal connections support and rebel alliance legs. The software that I use to scale/slice and prep all STL files is the amazing <a href="https://ultimaker.com/software/ultimaker-cura" target="_blank">Cura </a>software.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwXJYoUJ5PbPZQYcO1OuOqwPg7BVbeLR5FGJjpIi3Z8kCMiiLMCVU10Y0FevLIH_a0vXAKAWv0MDtUxtVUeUt6B4o0q62bxQ9i9LeiRtF4pnYGk2Pws73vDIYBV7jdCb6f7dFyzRwMG3lO/s1600/Star+wars+2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwXJYoUJ5PbPZQYcO1OuOqwPg7BVbeLR5FGJjpIi3Z8kCMiiLMCVU10Y0FevLIH_a0vXAKAWv0MDtUxtVUeUt6B4o0q62bxQ9i9LeiRtF4pnYGk2Pws73vDIYBV7jdCb6f7dFyzRwMG3lO/s320/Star+wars+2.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvUx0kS31xBlYBpUKZRhyMFkDE4hTWuxVAKm3eQ33hghtU2uOAFDUU9vQHNZy8eZNPdug2Sv8tfNGDMK_aArlUFWppBh-gZqKB3w2LgqPVvLGdWWhZvseD5FQNQB3GHBDiOfh-95ZwFYKI/s1600/Star+wars+3.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvUx0kS31xBlYBpUKZRhyMFkDE4hTWuxVAKm3eQ33hghtU2uOAFDUU9vQHNZy8eZNPdug2Sv8tfNGDMK_aArlUFWppBh-gZqKB3w2LgqPVvLGdWWhZvseD5FQNQB3GHBDiOfh-95ZwFYKI/s320/Star+wars+3.jpg" width="240" /></a></div>
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Another cool 3D print (credit to <a href="https://www.thingiverse.com/thing:308335" target="_blank">MakerBot</a> for sharing the files) was a present for my father in law that is a huge fan of Jurassic park and is fighting cancer, the print of a T-Rex skull including the stand, I used a gold filament for the skull and grey for the stand and it turned out very well, the T-Rex looks very well decorating his sitting room now and most important made him happy ;-).</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFdvAOYKaA8fSCNZATaQAjTzOe5qWOwiXHcS2TTeVKzpcMzufNYcBV_W9WOdpGDRub5cVlKQjUXhAdZp-aVXmjmrETHBiXRXEGiVg0nsCpG5QnNC7EVOcKP8R2s9wnQ4bHWgUXKuCMs8Bc/s1600/T-Rex1.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFdvAOYKaA8fSCNZATaQAjTzOe5qWOwiXHcS2TTeVKzpcMzufNYcBV_W9WOdpGDRub5cVlKQjUXhAdZp-aVXmjmrETHBiXRXEGiVg0nsCpG5QnNC7EVOcKP8R2s9wnQ4bHWgUXKuCMs8Bc/s320/T-Rex1.jpg" width="320" /></a></div>
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One thing I learned about this print is to make sure that there is a good infill % for small areas such as the T-Rex teeth that I had to super glue 2 of them after as I yanked them off with the support.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEht__sPYa4O9u365_XgQ2nTef9qLYHbf2o087F568zFwvgpYpRL_ILfwh3O9LkZi-mrfJwq1XTN8BwUNqSOHc0KB7NxRA49MmQufY3E6Eb_M-f2K034qbdk59d7vn_xDHeanAF-1j2aG8s_/s1600/T-Rex2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEht__sPYa4O9u365_XgQ2nTef9qLYHbf2o087F568zFwvgpYpRL_ILfwh3O9LkZi-mrfJwq1XTN8BwUNqSOHc0KB7NxRA49MmQufY3E6Eb_M-f2K034qbdk59d7vn_xDHeanAF-1j2aG8s_/s320/T-Rex2.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu22wrOtcEqcLY5GASVq6juzKXtMUn7oJFtDQ6XdqAI8Rm5WaT7qI1Fn09gUuhqHtKl6SBYuhAb47E74gpxsdEMHUQ5PXE5gHjtdDKNIst-_zvmLg1qmi2zO59aW4qybufNlrXhdKy327x/s1600/T-Rex3.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu22wrOtcEqcLY5GASVq6juzKXtMUn7oJFtDQ6XdqAI8Rm5WaT7qI1Fn09gUuhqHtKl6SBYuhAb47E74gpxsdEMHUQ5PXE5gHjtdDKNIst-_zvmLg1qmi2zO59aW4qybufNlrXhdKy327x/s320/T-Rex3.jpg" width="240" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7JFnVd-qg1mNe3YUxxVmSN2vzQ1AckqIqNzdE8nJ-ISl3yMWDeGwRk-_oP8qr0fbMsMRdlh7RIDfxNJZXkIIFOoeV_W1n2EuFfHC3Xq7m9tARMGUY8uj2Wtr1uAKq2B6jrMMCpRR9Bn1Y/s1600/Yogi+man+4.PNG" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em; text-align: center;"><img border="0" data-original-height="800" data-original-width="1600" height="200" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7JFnVd-qg1mNe3YUxxVmSN2vzQ1AckqIqNzdE8nJ-ISl3yMWDeGwRk-_oP8qr0fbMsMRdlh7RIDfxNJZXkIIFOoeV_W1n2EuFfHC3Xq7m9tARMGUY8uj2Wtr1uAKq2B6jrMMCpRR9Bn1Y/s400/Yogi+man+4.PNG" width="400" /></a>The print on the right is my pride and joy as this was the first experiment I did with <a href="https://en.wikipedia.org/wiki/Photogrammetry" target="_blank">Photogrammetry</a>, I took 80 photos of a wooden statue - The Legend of the Yogi Man (Orang Malu) also known as “The Weeping Buddha” or “Shy Man Buddha". I had the wooden statue over 10 year in my sitting room and it was perfect opportunity to try the Photogrammetry with a nice round object. I used <a href="https://www.autodesk.com/products/recap/overview" target="_blank">Autodesk ReCap Photo </a>software to generate the 3D shape from the puzzle of images, when I saw it the first time it was like magic, taking something from the real world and replicating it into a 3D object that can be manipulated in size and other features.</div>
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I experiment with a couple of prints and the best part there is no need for any support for this 3D printing and the final result is really cool, especially with high infill it makes the print feel heavy and chunky when holding it.<br />
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In the print below I tested Photogrammetry with another statue and it turned out ok but the details where not as good as the first single Yogi statue, I figure I had to take more images from more angles so the final 3D object is more complete.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_9xvmulhK2Bv_VWMRz6skFFsE6RBAy2Dhbe30zZTEkSSvRsDFJ61vbej25k8MHSE9yOcXbECoXUlgRdXjEWmjutl8Z_TrE1yUx0_GT52-4nmSMU6SyDmsQOw_tPO0gb-egFVE2E7Lr7lL/s1600/Yogi+man+3.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_9xvmulhK2Bv_VWMRz6skFFsE6RBAy2Dhbe30zZTEkSSvRsDFJ61vbej25k8MHSE9yOcXbECoXUlgRdXjEWmjutl8Z_TrE1yUx0_GT52-4nmSMU6SyDmsQOw_tPO0gb-egFVE2E7Lr7lL/s320/Yogi+man+3.jpg" width="320" /></a></div>
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I plan to try at some point next year to use some of the 3D plastic printings into metal casting, one of the main advantages of the 3D printing where before it took me hours to make for example a pattern of a sign now I can quickly design and print the pattern. </div>
FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-6184833311038625302018-10-30T15:03:00.002-07:002018-11-01T14:37:17.971-07:00Styrofoam skulls into solid aluminum - (Lost Foam Casting) ♻<div style="text-align: left;">
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In this video/tutorial I created a solid aluminum wreath skulls for Halloween, I used the Lost Foam casting method with my home made furnace to make the aluminum casting, the process is super simple and the preparation of the casting mold is very quick.</div>
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As always I am recycling ♻ old aluminum scrap into something new, most important is promoting the recycling awareness by providing different ideas for projects. </div>
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FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-73443650879160176762018-10-30T14:56:00.003-07:002018-10-30T14:56:35.541-07:00How To Make - Solid Aluminum Ghost Mask - Halloween Decoration ♻ <div style="text-align: justify;">
In this video I have created a solid aluminum ghost mask for Halloween and a small mummy statue, I started with a plastic ghost mask like the one in the horror movie Scream, I created the pattern using plaster and varnish (to prevent the sand from sticking and to get better casting results). The solid aluminum ghost mask turned out amazing.<br />
All my aluminum, castings are done using a homemade furnace and scrap aluminum. So as always my main message is to create awareness of recycling and to inspire to try and re-use ♻ </div>
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FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-33669385222262751742018-10-30T14:49:00.001-07:002018-10-30T14:51:19.684-07:00Halloween Skull decoration into solid aluminum - Lost Foam Casting ♻ <div style="text-align: justify;">
In this tutorial video you can learn how to create your own aluminum skull-bones ☠️ decoration for Halloween or just for the fun of it, ;-)</div>
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As always I am recycling old scrap aluminum into something new, most important is promoting the recycling awareness by providing different ideas for projects ♻</div>
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FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-43567734517826023102018-10-30T14:39:00.001-07:002018-10-30T14:39:22.867-07:00Special Zombie Apocalypse - Spike Ball Aluminum Lost Foam Casting<div style="text-align: justify;">
Spike ball for zombie apocalypse - In this video I will show you the stages of how I made an aluminum spike ball using lost foam casting method. The aluminum casting turned out very well and surprisingly ;-), the handle is made from scrap metal such as bolt, nuts metal loop and old fishing chain.</div>
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As always I am recycling old scrap aluminum into something new, most important is promoting the recycling awareness by turning this waste into something new. I hope you enjoy the video feel free to like subscribe or drop me a comment ;-)</div>
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FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-66134892756312515162018-10-30T14:27:00.002-07:002018-10-30T14:30:13.208-07:00Silly Paper Weight - Lost Foam Aluminum Casting<div style="text-align: justify;">
This is a short video of my lost foam aluminum casting experiment, I just glued some art and craft Styrofoam ball I found in a local craft shop. This silly project gave me idea for my next video - coming up soon demonstrating how to cast solid aluminum medieval spiked ball. As always all my metal casting projects are made from recycled aluminum, the main purpose of my videos is to increase recycling awareness. I hope you enjoy the video feel free to like subscribe or drop me a comment.</div>
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FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-61788031615757219132018-10-30T14:19:00.002-07:002018-10-30T14:19:30.973-07:00Lost Foam Aluminum casting - Heart Chain<div style="text-align: justify;">
In this video I will show you how to create a solid aluminum Valentine's Hearts chain using (polystyrene) lost foam casting process, as always I am recycling old scrap aluminum into something new, most important is promoting the recycling awareness and what can be done with waste aluminum.</div>
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FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-4793683613870730562016-07-26T13:36:00.001-07:002016-07-26T13:58:09.637-07:00Solid aluminum pistol casting from recycled scrap aluminum. <div class="separator" style="clear: both; text-align: center;">
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This is the 1st part of how to cast a solid aluminum pistol using a homemade furnace and recycled scrap aluminum.</h2>
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This is the 2nd part of how to cast a solid aluminum pistol using a homemade furnace and recycled scrap aluminum.</h2>
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FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-17923718369198541282015-02-22T13:32:00.001-08:002015-03-07T09:30:18.612-08:00Aluminum boat cleat casting using a homemade furnace + tutorial of this project.<span class="goog-text-highlight">Hi everyone, so this is my first post for 2015, in my last post I made a tutorial of how to prepare a sand mould using a </span><b><span class="goog-text-highlight">solid pattern</span></b><span class="goog-text-highlight">. In this post I will explain how I made a solid aluminum boat cleat using a <b>split pattern</b> with my homemade furnace.</span><br />
I have also created another tutorial this time explaining how to create the split pattern for this type of aluminum casting.<br />
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<span class="">This special request came from my brother that is taking a course in becoming a yacht skipper.</span></div>
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He doesn't have a Yacht yet.... but a boat cleat is a good start ;-)<br />
So first I have made a quick sketch design using Google Sketchup.<br />
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<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHYKx0VI6UoIX7czxbZeM4areZLiRbk7ML4-l3WO7B6j_V0W6EBfEbm5x6bUgKDCK4gj9xsY1Xv7kFUb2G3vSlPH4WT_HxB0xdHwUPRvRn7AW0LH6_-7gVIRTipEJG7k3CAinF4n1vMlOi/s1600/boat+cleat+Sketch0+(Medium).JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em; text-align: center;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHYKx0VI6UoIX7czxbZeM4areZLiRbk7ML4-l3WO7B6j_V0W6EBfEbm5x6bUgKDCK4gj9xsY1Xv7kFUb2G3vSlPH4WT_HxB0xdHwUPRvRn7AW0LH6_-7gVIRTipEJG7k3CAinF4n1vMlOi/s1600/boat+cleat+Sketch0+(Medium).JPG" height="60" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcuPU3JaYwbBx5EO2p6dZeQp8ok-7pjvobQqAz-OGOwQAj_Re_tcp7Coixs_SSL0w5gmhSlDl0ZTgUd_OJepV7w03hkUdZCRLBU23eTIadD1L_ONA2e0LgA6yhep9P4gsHwF5sQ0qcnkPc/s1600/boat+cleat+sketch1+(Medium).JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcuPU3JaYwbBx5EO2p6dZeQp8ok-7pjvobQqAz-OGOwQAj_Re_tcp7Coixs_SSL0w5gmhSlDl0ZTgUd_OJepV7w03hkUdZCRLBU23eTIadD1L_ONA2e0LgA6yhep9P4gsHwF5sQ0qcnkPc/s1600/boat+cleat+sketch1+(Medium).JPG" height="60" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioZnVTw-8TW-Am8f4ZtL4zSwBW6jI2QLxl3yraME8434vm8dEYjfMCan2PMW7W22WQk8agqmkx2zjvE8iEMhGFt7DnLdf2hoT_G_hfrfOoiswxooX9-slgZnV0A1hs6tr0ZLwfBy3FEU1R/s1600/boat+cleat+sketch3+(Medium).JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioZnVTw-8TW-Am8f4ZtL4zSwBW6jI2QLxl3yraME8434vm8dEYjfMCan2PMW7W22WQk8agqmkx2zjvE8iEMhGFt7DnLdf2hoT_G_hfrfOoiswxooX9-slgZnV0A1hs6tr0ZLwfBy3FEU1R/s1600/boat+cleat+sketch3+(Medium).JPG" height="60" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjErJK_BdWbSpGrktDGabmrp5NuwnjNjN4Lg177nXC0oEXEkbvbWC4qe6iWPSnpCXmb2j-JIEPGMdqoUR59gDAgxKJ87PPRGQaVi1GYOh-p-9kahDjrrUs_1UCSAYKNhe045xug6CZmaFi/s1600/boat+cleat+sketch2+(Medium).JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjErJK_BdWbSpGrktDGabmrp5NuwnjNjN4Lg177nXC0oEXEkbvbWC4qe6iWPSnpCXmb2j-JIEPGMdqoUR59gDAgxKJ87PPRGQaVi1GYOh-p-9kahDjrrUs_1UCSAYKNhe045xug6CZmaFi/s1600/boat+cleat+sketch2+(Medium).JPG" height="60" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLyrwK41cKZbJFaQ0B0dFDAux11l2jysSkQWh_3ZLfzGs7gZU7UUg5ISVNL2C8BlGBhE2yEu2cJznvNjRZb7dLiRTTkTRy-O5St86b5mVwTqrLji0EkjybQbPNyfWIRbKBHNZ1FTNYeZ1C/s1600/boat+cleat+sketch5+(Medium).JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLyrwK41cKZbJFaQ0B0dFDAux11l2jysSkQWh_3ZLfzGs7gZU7UUg5ISVNL2C8BlGBhE2yEu2cJznvNjRZb7dLiRTTkTRy-O5St86b5mVwTqrLji0EkjybQbPNyfWIRbKBHNZ1FTNYeZ1C/s1600/boat+cleat+sketch5+(Medium).JPG" height="60" width="150" /></a></td>
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After I had some idea and plan as to how I want the pattern to look like I started making it using MDF as the main material for the pattern. The split pattern is constructed from 2 half's of 18mm MDF. </div>
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<span class="">The pattern size is 100mm height, 300mm width & 36mm in depth. I started by making a template of the boat cleat transferring it to a sheet of 8mm MDF, once I had the template and the desired shape cut with a jigsaw I used the template as a guide for my electric router, I transferred the boat cleat shape into the 2 parts of MDF by using the template. As I did not have a long enough straight bit for my router (+36mm) I used 2 bits, a short straight bit and a flush trim bit with bearing running it around the template. It took a bit longer but the end result was satisfying and accurate.</span><br />
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(Just a quick note as how I connected the 2 split parts, I connected the 2 parts of MDF with small pins making sure they will not be in the way of the router bit. )<br />
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After the pattern was complete the same pins are used to align the 2 half's when placed into the foundry flask, it is very important to make sure that the 2 parts are aligned accurately for a good aluminum casting results.
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<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHnRQD0dFrNrQ1TKBIknPbO7Q1pI6bizO-ZTsGYYBX21lUva5vaTrghkMGmk9yVecpJxSw6u5mpRhSjcT8k1NWqkXD66vPlH44p2ZmdbQ3qSO5ihfANPjAW-NRQYwYqfYSaRy3S-dQIfg_/s1600/home+foundry+split+pattern+1.JPG" imageanchor="1" style="margin-left: 0em; margin-right: 0em; text-align: left;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHnRQD0dFrNrQ1TKBIknPbO7Q1pI6bizO-ZTsGYYBX21lUva5vaTrghkMGmk9yVecpJxSw6u5mpRhSjcT8k1NWqkXD66vPlH44p2ZmdbQ3qSO5ihfANPjAW-NRQYwYqfYSaRy3S-dQIfg_/s1600/home+foundry+split+pattern+1.JPG" height="100" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieqmFZi5xTccHp5FXY2_JQ4UudCb-h2IywJ97wUdkwZeh71Sbtwawx09p7WwWzDHjx4-9TxU9aSIFxtHKOBiZzgZPLo5EOazLUadn_b9G_9nKoXzPt3B_cODyVQ6InxvUWz1djqBP3jz-s/s1600/home+foundry+split+pattern+2.JPG" imageanchor="1" style="margin-left: 0em; margin-right: 0em; text-align: center;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieqmFZi5xTccHp5FXY2_JQ4UudCb-h2IywJ97wUdkwZeh71Sbtwawx09p7WwWzDHjx4-9TxU9aSIFxtHKOBiZzgZPLo5EOazLUadn_b9G_9nKoXzPt3B_cODyVQ6InxvUWz1djqBP3jz-s/s1600/home+foundry+split+pattern+2.JPG" height="100" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2JmYpGiyT7bzz5ZTC5AnO6YtQsmrwilHxq1ZO2c6rkZeMgNmyautkepBiSTSKVj5apNhF87o8It_XYLqq3YtylcE3IQWIVnP6eB7GFCAT_fH3ExzEpNb6y5ZcGKFaaND-k0LsjqhDkHdv/s1600/home+foundry+split+pattern+7.JPG" imageanchor="1" style="clear: left; margin-bottom: 0em; margin-right: 0em; text-align: center;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2JmYpGiyT7bzz5ZTC5AnO6YtQsmrwilHxq1ZO2c6rkZeMgNmyautkepBiSTSKVj5apNhF87o8It_XYLqq3YtylcE3IQWIVnP6eB7GFCAT_fH3ExzEpNb6y5ZcGKFaaND-k0LsjqhDkHdv/s1600/home+foundry+split+pattern+7.JPG" height="100" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrsp7wTeBc-IFImB02obaWmiRy2sz1MwgLTRJUyQQrv6KapWnrm6-kOIbedfiTzXxuqHa7xro2d2mWwPDVgAhX_ML7liP_bcP7H1NRSPkccsh5NXIYufDF5NMp-oll7_VBZnkm6VU6VDKU/s1600/home+foundry+split+pattern+3.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em; text-align: center;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrsp7wTeBc-IFImB02obaWmiRy2sz1MwgLTRJUyQQrv6KapWnrm6-kOIbedfiTzXxuqHa7xro2d2mWwPDVgAhX_ML7liP_bcP7H1NRSPkccsh5NXIYufDF5NMp-oll7_VBZnkm6VU6VDKU/s1600/home+foundry+split+pattern+3.JPG" height="100" width="150" /></a></td>
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<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmEPzz_UGkZkZrq6719A8tRL3azlKaf4tzdaQQYa_z5wmKC_xaQAc9P5M3cW1lTTWvsYNCSpLy0oLvRy8gVjhlzKQL7gI_XSlsU_hCgfiqe6AQkzCph5h-RK4KmBVHypgGcnc6qpxWqyr_/s1600/home+foundry+split+pattern+6.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmEPzz_UGkZkZrq6719A8tRL3azlKaf4tzdaQQYa_z5wmKC_xaQAc9P5M3cW1lTTWvsYNCSpLy0oLvRy8gVjhlzKQL7gI_XSlsU_hCgfiqe6AQkzCph5h-RK4KmBVHypgGcnc6qpxWqyr_/s1600/home+foundry+split+pattern+6.JPG" height="100" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWwIHaWXnfA27zUMnR-903uC1aVkfwyOvat_HXWhbnnuFdmmmx8wE1wTC6a3JtYnl5GMDDzH4mvvru9ifWGXztfhAPr1V6NxBpdNhuLOkAaFmO_kdiAcjnAhwOmuOk2VEboy0rc5aTLWUg/s1600/home+foundry+split+pattern+8.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWwIHaWXnfA27zUMnR-903uC1aVkfwyOvat_HXWhbnnuFdmmmx8wE1wTC6a3JtYnl5GMDDzH4mvvru9ifWGXztfhAPr1V6NxBpdNhuLOkAaFmO_kdiAcjnAhwOmuOk2VEboy0rc5aTLWUg/s1600/home+foundry+split+pattern+8.JPG" height="100" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpzAFb0pzbwkZaJR_U20chhxizybE2rVtY-sW2mDZfI9-8nxgGym-Apjm9IO3_v4ZLtjMhYCxKLk-aExIyezF8Gz6EvK8NAhFMWQr9KiRkeWX8UvoVJmFejuOADqGMp3HxDgCI7Axyf5Fc/s1600/home+foundry+split+pattern+5.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpzAFb0pzbwkZaJR_U20chhxizybE2rVtY-sW2mDZfI9-8nxgGym-Apjm9IO3_v4ZLtjMhYCxKLk-aExIyezF8Gz6EvK8NAhFMWQr9KiRkeWX8UvoVJmFejuOADqGMp3HxDgCI7Axyf5Fc/s1600/home+foundry+split+pattern+5.JPG" height="100" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9kUtXy80PR6rNPw1WRHSmVRfYgZeCQhJ-U2SKl1D7ngjjOBfOoyRPS7QjzCZt0gFaoNWean_1q9I_yhxBhrnPk0WKCPti6FCDkTs2CYwGzp1Afj2NF2G1wTAtrnaaDstidVXpgtT3_Cio/s1600/home+foundry+split+pattern+9.JPG" imageanchor="1" style="clear: left; margin-bottom: 0em; margin-right: 0em; text-align: center;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9kUtXy80PR6rNPw1WRHSmVRfYgZeCQhJ-U2SKl1D7ngjjOBfOoyRPS7QjzCZt0gFaoNWean_1q9I_yhxBhrnPk0WKCPti6FCDkTs2CYwGzp1Afj2NF2G1wTAtrnaaDstidVXpgtT3_Cio/s1600/home+foundry+split+pattern+9.JPG" height="100" width="150" /></a></td>
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Next step after creating the boat cleat pattern from the MDF : I used my table router to round all the corners and create a groove in the MDF pattern giving it a depth and much more of a 3D attractive look.</div>
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In the next images you can see the stages and the different bits that I have used for the table router.
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<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYMv3PN3JacrnIGBXMYPdLAM1emZLcaAbe7SiFN47rQevzL_j2w3XRtZEFLpI_6ZwKdy7zdEWJjkj08ebI-QAaIcNHPcx0NzslgwBXXm4n5vOLlM-L-m1XPZ-WjDRFOM7hyphenhyphendh1MYmYxsi_/s1600/home+foundry+split+pattern+router+1.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYMv3PN3JacrnIGBXMYPdLAM1emZLcaAbe7SiFN47rQevzL_j2w3XRtZEFLpI_6ZwKdy7zdEWJjkj08ebI-QAaIcNHPcx0NzslgwBXXm4n5vOLlM-L-m1XPZ-WjDRFOM7hyphenhyphendh1MYmYxsi_/s1600/home+foundry+split+pattern+router+1.JPG" height="100" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEoWaO2-ZfgV00IvXsvDiel7FMUBMz1Q-OSd4IoWFttYCS3GmEySeaeVwt9jnlDi3tpqcghOPE45v9Jwj0bTshxlosEc2n3fWVHWUHhR_cEamT4PRyMEW_BwHgExo7WAZlVZZg1Dwq_ai-/s1600/home+foundry+split+pattern+router+2.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEoWaO2-ZfgV00IvXsvDiel7FMUBMz1Q-OSd4IoWFttYCS3GmEySeaeVwt9jnlDi3tpqcghOPE45v9Jwj0bTshxlosEc2n3fWVHWUHhR_cEamT4PRyMEW_BwHgExo7WAZlVZZg1Dwq_ai-/s1600/home+foundry+split+pattern+router+2.JPG" height="100" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOmOc7_Iaw8XJkQoNsMPURj0qr_hTf1PI_4pKyWToIht3rUcvgrdq9KVFu9aQQZBdAV0ndt0u5b3P-hFeUJ8cKGEOE6MuE8dxEMtXl20Hg_k0oe6KpHKIWjgTGAlXQj0tKBtssAAPmL4MW/s1600/home+foundry+split+pattern+router+3.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOmOc7_Iaw8XJkQoNsMPURj0qr_hTf1PI_4pKyWToIht3rUcvgrdq9KVFu9aQQZBdAV0ndt0u5b3P-hFeUJ8cKGEOE6MuE8dxEMtXl20Hg_k0oe6KpHKIWjgTGAlXQj0tKBtssAAPmL4MW/s1600/home+foundry+split+pattern+router+3.JPG" height="100" title="Aluminum boat cleat split pattern made of MDF" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcUFW-MmdH8wluoFDl8GuEwCJQQ4vuezTfP-zTwL-Wc8sUObua6C5DDc6ze__Xv1U06b5nhfxmUDsvpvJHldxNKYDqYiCEFbPxhLRarxXz1DC1zlqsyO8FNn9YIZyMuyf9wrqRZVOUackq/s1600/home+foundry+split+pattern+router+4.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcUFW-MmdH8wluoFDl8GuEwCJQQ4vuezTfP-zTwL-Wc8sUObua6C5DDc6ze__Xv1U06b5nhfxmUDsvpvJHldxNKYDqYiCEFbPxhLRarxXz1DC1zlqsyO8FNn9YIZyMuyf9wrqRZVOUackq/s1600/home+foundry+split+pattern+router+4.JPG" height="100" title="Aluminum boat cleat split pattern" width="150" /></a></td>
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MDF is a great and easy material to shape, however as it is made from medium density fiber there are a few important highlights: 1st - its important to work with dust extractor and a good mask avoiding inhalation of the MDF dust. 2nd - as MDF has very rough edges when being cut it is important to seal the MDF pattern, I used a wood filler to improve the angle (Draft's) of the pattern and after the wood filler was dry I sanded the MDF pattern using different grades of sand paper until a smooth finishing was achieved. Last thing that I did was coating the pattern with gloss varnish, I had concerns that I will not be able to separate the 2 half's as I varnished the pattern with the 2 half's connected but to my surprise it was very easy to separate between the two sides and from this point the pattern was ready to be used for the sand mould.</div>
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<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0uwMUFeOu1Z2xXdk_0on4zed0C_gxB6sNPDjZ9XxgNdOKTtFQ0xYcegvCw5JL7E5ZhbfVKVnlpPrnU-B7tc2II3edVkAnPBJyP6XwW9OAteB1wlgaUszaFQ3Mt5D_Mrc3zb3j86lxpEhS/s1600/home+foundry+split+pattern+of+a+boat+cleat+1.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0uwMUFeOu1Z2xXdk_0on4zed0C_gxB6sNPDjZ9XxgNdOKTtFQ0xYcegvCw5JL7E5ZhbfVKVnlpPrnU-B7tc2II3edVkAnPBJyP6XwW9OAteB1wlgaUszaFQ3Mt5D_Mrc3zb3j86lxpEhS/s1600/home+foundry+split+pattern+of+a+boat+cleat+1.JPG" height="100" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxSPd1-ImGFM4Hy2A7GkY7sJtzM5rSoz4z2FOLWvJkLD0J2eFkxt3fO1OIZzAssfO6ln80q8DIT3gPvdieRutneWrhTQn_f5EkbS9gsXfm4qTgC3dwQWbk9Xikh_WNevoODSb_2Xu8XZub/s1600/home+foundry+split+pattern+of+a+boat+cleat+2.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxSPd1-ImGFM4Hy2A7GkY7sJtzM5rSoz4z2FOLWvJkLD0J2eFkxt3fO1OIZzAssfO6ln80q8DIT3gPvdieRutneWrhTQn_f5EkbS9gsXfm4qTgC3dwQWbk9Xikh_WNevoODSb_2Xu8XZub/s1600/home+foundry+split+pattern+of+a+boat+cleat+2.JPG" height="100" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiknyn4mPRvAH0Nn7S2YI1HlDki4JusXH7LmprQsMzQ9GwoQawC9qt9JKXCYr8q9jHfY6IxPM_f7pTKHCejfJ7j5HJJEikhmMJTCJTBICUS0_X9asuJDza46571UcB8Du61dTg0lznEpR3p/s1600/home+foundry+split+pattern+of+a+boat+cleat+3.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiknyn4mPRvAH0Nn7S2YI1HlDki4JusXH7LmprQsMzQ9GwoQawC9qt9JKXCYr8q9jHfY6IxPM_f7pTKHCejfJ7j5HJJEikhmMJTCJTBICUS0_X9asuJDza46571UcB8Du61dTg0lznEpR3p/s1600/home+foundry+split+pattern+of+a+boat+cleat+3.JPG" height="100" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKUoqywUxP3w5OZnQvBZQ82Vp2xGTGKiZcnivpbE6axSp2_Y6kZuIehzNRIAw3x3gVfGiqThLToE5wnO55CxgsSnN_8SxLjqLsnhrKjfElvd2x-uXZ-xCGuc3N79ygGWQsG957R1HN-J9U/s1600/home+foundry+split+pattern+of+a+boat+cleat+4.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKUoqywUxP3w5OZnQvBZQ82Vp2xGTGKiZcnivpbE6axSp2_Y6kZuIehzNRIAw3x3gVfGiqThLToE5wnO55CxgsSnN_8SxLjqLsnhrKjfElvd2x-uXZ-xCGuc3N79ygGWQsG957R1HN-J9U/s1600/home+foundry+split+pattern+of+a+boat+cleat+4.JPG" height="100" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4l1_DAP-4rHks-Yqmao3VWACq5jbx8_a3NQlw4zPUnLtnGwk5Fq4-dgCv5gH40Z0i5qEUWmdqhL3eT6Jaf817weMKHgRAC1jGWocauMBcMkkRvsj8h5nASzVbaI1RMTM429ozsQ7IYNHd/s1600/MDF+pattern+made+for+aluminum+metal+casting+using+a+homemade+furnace.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4l1_DAP-4rHks-Yqmao3VWACq5jbx8_a3NQlw4zPUnLtnGwk5Fq4-dgCv5gH40Z0i5qEUWmdqhL3eT6Jaf817weMKHgRAC1jGWocauMBcMkkRvsj8h5nASzVbaI1RMTM429ozsQ7IYNHd/s1600/MDF+pattern+made+for+aluminum+metal+casting+using+a+homemade+furnace.JPG" height="70" width="150" /></a></td>
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At this point the split pattern was ready after adding 2 coats of varnish, the surface was glossy and smooth, I made the sand mould using a wooden flask & oil bonded sand for a good finishing. I did have some concerns that the sand mould might break around the straight sections of the pattern but the sand mould turned out very well with minor damages when I removed the split pattern.
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<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKufhvMUVKnCg3HB6WZLGN0_V3S7yiqz6tQ6b-rjgx7f3JtrpNi8DO5moQXZP9RIjTQh7mftzlDrDPMnlVR-YJpYngqm2YmGTd5iwg82bOqWEVhf98wNEx30mn3RuoPcpcGgDA2uUPH4KA/s1600/aluminum+boat+cleat+foundry+sand+casting+1.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKufhvMUVKnCg3HB6WZLGN0_V3S7yiqz6tQ6b-rjgx7f3JtrpNi8DO5moQXZP9RIjTQh7mftzlDrDPMnlVR-YJpYngqm2YmGTd5iwg82bOqWEVhf98wNEx30mn3RuoPcpcGgDA2uUPH4KA/s1600/aluminum+boat+cleat+foundry+sand+casting+1.JPG" height="100" title="foundry sand mould using a split pattern" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvRVzUahu4BMW_GfFG5c5lHaylxGqqnomzCanFv5ND8HQsKEDyGQhEhLCHeLOAV34WfkEQF5-O0qKD7R34RUGVByUCNXQ3v6obmLkm8owjvI930ruj9r3oXVITIuTV3y_vmiBphrvX5S9L/s1600/aluminum+boat+cleat+foundry+sand+casting+2.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvRVzUahu4BMW_GfFG5c5lHaylxGqqnomzCanFv5ND8HQsKEDyGQhEhLCHeLOAV34WfkEQF5-O0qKD7R34RUGVByUCNXQ3v6obmLkm8owjvI930ruj9r3oXVITIuTV3y_vmiBphrvX5S9L/s1600/aluminum+boat+cleat+foundry+sand+casting+2.JPG" height="100" title="foundry sand mould using a split pattern" width="150" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCFCADG1R4pShwGwITuFMVptl2jCqStTHV45IaNaR1IgQcdArJ0sfDBX71LLUaiHtX1Q7gYrFFUevQZKu3Y9nrGB85TS3kVbxSuk1jB681hJcBs2mBxZv4B7RXT0excBBcPzDzgsosTuwx/s1600/aluminum+boat+cleat+foundry+sand+casting+3.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCFCADG1R4pShwGwITuFMVptl2jCqStTHV45IaNaR1IgQcdArJ0sfDBX71LLUaiHtX1Q7gYrFFUevQZKu3Y9nrGB85TS3kVbxSuk1jB681hJcBs2mBxZv4B7RXT0excBBcPzDzgsosTuwx/s1600/aluminum+boat+cleat+foundry+sand+casting+3.JPG" height="100" title="foundry flask with mould sand ready for the aluminum casting" width="150" /></a></td></tr>
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After removing the split pattern from the sand mould I created the gating system in the sand, a poor gating system can lead to casting defects so this is a very important stage when preparing the sand mould, once the gating system is complete it is ready to be filled with molten aluminum.</div>
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Next I closed and clamped the flask and started to heat my homemade furnace, after the aluminum was in a molten stage I poured it into the flask and opened it after 1 hour, the solid aluminum boat cleat turned out very well with minor imperfections that were very easy to clean and fix.<br />
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In the next set of images you can see the solid aluminum boat cleat after taking it out from the sand mould. I used a reciprocating saw with a metal blade to quickly cut off the risers. Last part was to clean the aluminum casting and give it a light polish.
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<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKQkuMXFhQfixidJfrUnUI98GhAd1-sx-ESGREZLZAylzYwAOupjZR-II5bGTbW4fZg5hAtCd580Qelkfma-2_WSxdRXaLzM7uo9dzsy6oAZOp7b4fqW-ekTFZF2W2dqCWngZ6xladKCBg/s1600/aluminum+boat+cleat+casting+ready+for+polish+1.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><br /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVMbW5tBjyfawRhPk4F9M2HwNMaGaLPVnPeQ1_DP915E7WTE8FT6hnSWSIW6ITOhqdiTkxt9hR8iELE9HCTVpxYkWfjI010rlNM1FhcGhUuz3E4MLZ6PjhiV0S033iHR3B4b6Xi39Qrsf7/s1600/aluminum+casting+with+sprue+and+riser+1.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVMbW5tBjyfawRhPk4F9M2HwNMaGaLPVnPeQ1_DP915E7WTE8FT6hnSWSIW6ITOhqdiTkxt9hR8iELE9HCTVpxYkWfjI010rlNM1FhcGhUuz3E4MLZ6PjhiV0S033iHR3B4b6Xi39Qrsf7/s1600/aluminum+casting+with+sprue+and+riser+1.JPG" height="100" title="aluminum casting out of the foundry flask" width="140" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPivWLP5CpKM1JCVEXq9QotjSuyJxjGbl0UgOm1AuBVuoH9sSivPhUv9Hz4kllkh1o2aawriVLEXykVMcJMhN03bJ22ApwVJJ287kdocvE2qxobelsMhyphenhyphenHKjz5fhE2JYpMSHjaoaVV7ju3/s1600/aluminum+casting+with+sprue+and+riser+2.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPivWLP5CpKM1JCVEXq9QotjSuyJxjGbl0UgOm1AuBVuoH9sSivPhUv9Hz4kllkh1o2aawriVLEXykVMcJMhN03bJ22ApwVJJ287kdocvE2qxobelsMhyphenhyphenHKjz5fhE2JYpMSHjaoaVV7ju3/s1600/aluminum+casting+with+sprue+and+riser+2.JPG" height="100" title="aluminum casting out of the foundry flask with sprue and riser" width="140" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVVa67dTkTeL2kGXQKr5KiBYzK8LV9kRxDn5LsB-FliiDRnvsjhjQtDIQI_VjB-4w_o72KRO3wjZPYQ-5AqGMPRkXQ04gdHyqLkJVEH66sORyHf3arMs4-ftzPSLTz0EjKNghfytpo71zx/s1600/aluminum+casting+with+sprue+and+riser+3.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVVa67dTkTeL2kGXQKr5KiBYzK8LV9kRxDn5LsB-FliiDRnvsjhjQtDIQI_VjB-4w_o72KRO3wjZPYQ-5AqGMPRkXQ04gdHyqLkJVEH66sORyHf3arMs4-ftzPSLTz0EjKNghfytpo71zx/s1600/aluminum+casting+with+sprue+and+riser+3.JPG" height="100" title="cutting aluminum sprue and riser" width="140" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKQkuMXFhQfixidJfrUnUI98GhAd1-sx-ESGREZLZAylzYwAOupjZR-II5bGTbW4fZg5hAtCd580Qelkfma-2_WSxdRXaLzM7uo9dzsy6oAZOp7b4fqW-ekTFZF2W2dqCWngZ6xladKCBg/s1600/aluminum+boat+cleat+casting+ready+for+polish+1.JPG" imageanchor="1" style="clear: left; margin-bottom: 0em; margin-right: 0em; text-align: center;"><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKQkuMXFhQfixidJfrUnUI98GhAd1-sx-ESGREZLZAylzYwAOupjZR-II5bGTbW4fZg5hAtCd580Qelkfma-2_WSxdRXaLzM7uo9dzsy6oAZOp7b4fqW-ekTFZF2W2dqCWngZ6xladKCBg/s1600/aluminum+boat+cleat+casting+ready+for+polish+1.JPG" height="100" title="cleaned aluminum casting" width="140" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFMdNd6ksodkEABbhSvaNAoFFgQdJo_8xvpiqh0GSwusyWYHFDkJQweCoII2Ab5y2Z0mOxO8pWSdZIndy4rNIsb_h2lZXYR5N0gU3Tc374xpFrK1I9VF206hX1T6zz2sBVB8QISiS1ehG0/s1600/aluminum+boat+cleat+casting+ready+for+polish+2.JPG" imageanchor="1" style="clear: left; margin-bottom: 0em; margin-right: 0em; text-align: center;"><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFMdNd6ksodkEABbhSvaNAoFFgQdJo_8xvpiqh0GSwusyWYHFDkJQweCoII2Ab5y2Z0mOxO8pWSdZIndy4rNIsb_h2lZXYR5N0gU3Tc374xpFrK1I9VF206hX1T6zz2sBVB8QISiS1ehG0/s1600/aluminum+boat+cleat+casting+ready+for+polish+2.JPG" height="100" title="polished aluminum casting" width="140" /></a></td></tr>
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<div style="text-align: center;">
<u><b><span style="color: red;">Here is my tutorial video with most of the steps, creation of the sand mould and the actual molten aluminum pouring creating the solid aluminum boat cleat, enjoy:</span></b></u></div>
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<iframe allowfullscreen="" frameborder="0" height="315" src="https://www.youtube.com/embed/G1Re8gdSPDU?rel=0" width="560"></iframe></center>
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And here are a few images of the finished aluminum boat cleat.</center>
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<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_bDtKdSZLgpjyxaKAfTmfNTdEQF5OENXZuiZ_qI6Il_uwqV6Q0kw3bS2UjPJ22Sw8jWUiA9IUsHNLUYVvtu0Te6PYsISL8aeyAgH-C9xsp2FQ-RLmupIWNPdCpuDScibLUabEG5BYS6e1/s1600/aluminum+boat+cleat+finished+using+a+homemade+foundry+1.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><span id="goog_553902477"></span><img alt="aluminum casting of a boat cleat" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_bDtKdSZLgpjyxaKAfTmfNTdEQF5OENXZuiZ_qI6Il_uwqV6Q0kw3bS2UjPJ22Sw8jWUiA9IUsHNLUYVvtu0Te6PYsISL8aeyAgH-C9xsp2FQ-RLmupIWNPdCpuDScibLUabEG5BYS6e1/s1600/aluminum+boat+cleat+finished+using+a+homemade+foundry+1.JPG" height="150" title="aluminum casting of a boat cleat" width="200" /><span id="goog_553902478"></span></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3q_uXkpWERggCjIVylIK9RQL64JxkrQW2BnEk5EfnsnfNJ9ieXLJ_1_WFRwH-RQJ_HR5wuSbIFaB_OATS4F4C5yXzoKJHSMGBYi5I86E3dTYTYgtOoY6890iGWgVR4XQx71qQtDzUn1km/s1600/aluminum+boat+cleat+finished+using+a+homemade+foundry+2.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="aluminum casting of a boat cleat" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3q_uXkpWERggCjIVylIK9RQL64JxkrQW2BnEk5EfnsnfNJ9ieXLJ_1_WFRwH-RQJ_HR5wuSbIFaB_OATS4F4C5yXzoKJHSMGBYi5I86E3dTYTYgtOoY6890iGWgVR4XQx71qQtDzUn1km/s1600/aluminum+boat+cleat+finished+using+a+homemade+foundry+2.JPG" height="150" title="aluminum casting of a boat cleat" width="200" /></a></td>
<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKEVjRgAEXu9mIW2OwJ_G3xc8XMb1OmhmPB_3mYCbiyo20AoP5USsK4r1dZlrl-DMnFeVGcAzca2xrwO9wqhA6MtcMvu7Tcl5SKzpy0MCu46OU8T3zT5qEoAcRjNiftbO-m0wDvm48JW9g/s1600/aluminum+casting+and+foundry+split+pattern.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKEVjRgAEXu9mIW2OwJ_G3xc8XMb1OmhmPB_3mYCbiyo20AoP5USsK4r1dZlrl-DMnFeVGcAzca2xrwO9wqhA6MtcMvu7Tcl5SKzpy0MCu46OU8T3zT5qEoAcRjNiftbO-m0wDvm48JW9g/s1600/aluminum+casting+and+foundry+split+pattern.JPG" height="150" title="aluminum casting and foundry pattern" width="200" /></a></td></tr>
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FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-41677504590992088372014-12-09T13:54:00.002-08:002014-12-19T14:18:38.731-08:00Aluminum star casting using a homemade foundry + tutorialsIt has been some time since my last post as I was very occupied for the past year. In this post I will share with you how I have created a solid aluminum star from scrap aluminum.<br />
For the sand mould I used a plastic star pattern and oil bonded sand to create the sand mould.<br />
All the homemade foundry and foundry equipment that I used is D.I.Y.<br />
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Using this type of pattern is very easy to sand mould, one disadvantage is its not a split pattern so the sand mould process takes a bit longer.<br />
All that you need to start is to construct the foundry flask to hold the sand and either use foundry green sand or foundry oil bonded sand, and of course to construct a foundry ;-)...<br />
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So in the next set of images you can see the sand mould preparation process before and after removing the star pattern.<br />
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<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLto5lxZLA0cfsED5owHAG3kxybUqln2Pv9S7pWxHzqAlB6CLKyfk7iabzeQiHLz9grybeAHPAEuUuqObjjdYGXoWQjJugaWhgfQQqOhq4A40ey17-XQIknJm756CIrrzPJ-mtXnrqr53C/s1600/foundry+sand+mould+1.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLto5lxZLA0cfsED5owHAG3kxybUqln2Pv9S7pWxHzqAlB6CLKyfk7iabzeQiHLz9grybeAHPAEuUuqObjjdYGXoWQjJugaWhgfQQqOhq4A40ey17-XQIknJm756CIrrzPJ-mtXnrqr53C/s1600/foundry+sand+mould+1.JPG" height="100" width="150" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRDCkisQlH6Bo32Mg2V5g2yHvJZLPWHLTYSYgKKE40NorIUa65nhmDqxr39P53wD_qlFxVw0MdLr7TQd-qyoJyXT509ogamURMq18UNyvXH82bC1hExokSFXErcOlzQQFD22Hvo2Sl3zR1/s1600/foundry+sand+mould+2.JPG" imageanchor="1" style="margin-left: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRDCkisQlH6Bo32Mg2V5g2yHvJZLPWHLTYSYgKKE40NorIUa65nhmDqxr39P53wD_qlFxVw0MdLr7TQd-qyoJyXT509ogamURMq18UNyvXH82bC1hExokSFXErcOlzQQFD22Hvo2Sl3zR1/s1600/foundry+sand+mould+2.JPG" height="100" width="150" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLto5lxZLA0cfsED5owHAG3kxybUqln2Pv9S7pWxHzqAlB6CLKyfk7iabzeQiHLz9grybeAHPAEuUuqObjjdYGXoWQjJugaWhgfQQqOhq4A40ey17-XQIknJm756CIrrzPJ-mtXnrqr53C/s1600/foundry+sand+mould+1.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiW4EEqNuBO8eHuOvBQBwFLmOO-XKmMZTGfHkqc06_9XRrwBBpkz2hmr7R6icYJ46CkjxZD90liuZs_69bReNbI1Dg1nshBEvqGUyAR3SehaJuJE-ahC7JbCBJmYJPQ48adTic4ltTr7Uyk/s1600/foundry+sand+mould+3.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiW4EEqNuBO8eHuOvBQBwFLmOO-XKmMZTGfHkqc06_9XRrwBBpkz2hmr7R6icYJ46CkjxZD90liuZs_69bReNbI1Dg1nshBEvqGUyAR3SehaJuJE-ahC7JbCBJmYJPQ48adTic4ltTr7Uyk/s1600/foundry+sand+mould+3.JPG" height="100" width="150" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCyMTBhVosHQj0RKGgYn8L8Iyw809J56Qkwv0nxFw6-GywSgU-hp02ScDFevW8iahiSaYQFrrT29nxx4zzMvfc6yCi8SrrT0NcrJbwoUhg6Vj2MRPZoOsrRUhBKkW7Jiw79-yLiXl5Fhec/s1600/foundry+sand+mould+4.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCyMTBhVosHQj0RKGgYn8L8Iyw809J56Qkwv0nxFw6-GywSgU-hp02ScDFevW8iahiSaYQFrrT29nxx4zzMvfc6yCi8SrrT0NcrJbwoUhg6Vj2MRPZoOsrRUhBKkW7Jiw79-yLiXl5Fhec/s1600/foundry+sand+mould+4.JPG" height="100" width="150" /></a></td><td><br /></td></tr>
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In the next images you can see the sand mould after separating the cope from the drag part of the foundry flask. The sand mould turned out very well so the next step was to create the gating system for the molten aluminum to fill the inner cavity and that will form the solid aluminum star casting.<br />
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<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzJ-oApZzthTbeGrPp8eTSkGugqiFGLfhwOq2r-TpJyQGAUxjPWQOtKUpiMoYbTFGOGm5beMboyR3LiR-qK56wJbhu9fXBF-xjhLFtCSdUBc3fPMvO5pyi-8wvGOVcsmy4K2IBpbZloUN2/s1600/foundry+sand+mould+6.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzJ-oApZzthTbeGrPp8eTSkGugqiFGLfhwOq2r-TpJyQGAUxjPWQOtKUpiMoYbTFGOGm5beMboyR3LiR-qK56wJbhu9fXBF-xjhLFtCSdUBc3fPMvO5pyi-8wvGOVcsmy4K2IBpbZloUN2/s1600/foundry+sand+mould+6.JPG" height="100" width="150" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFdw2RRz3JNpM3AHGsP1Z5VpbQdXx8NN9kNSN08iOonEP_CXCt4Y0X_2Vvy-wRYaYX8NlkB6N159hk-Fmu_FUH-624Jt7JqXW3UPjv6LbW5MRSO4Fkhs2M_g5rkztMVtmfZVM6J0u8PNPm/s1600/foundry+sand+mould+7.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFdw2RRz3JNpM3AHGsP1Z5VpbQdXx8NN9kNSN08iOonEP_CXCt4Y0X_2Vvy-wRYaYX8NlkB6N159hk-Fmu_FUH-624Jt7JqXW3UPjv6LbW5MRSO4Fkhs2M_g5rkztMVtmfZVM6J0u8PNPm/s1600/foundry+sand+mould+7.JPG" height="100" width="150" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhr0e2MwT0v4in3vMQP8p2VneevJ9WdqzuuTrV1tI-E5aXI-1Ae77FwryQT0-R3YODn9F9E-jtFj5JRfiRNMiEuwo9OcHIDpMOrCKfoIpip4lciXPqqvki6XUrjSndC1kFpFta_SY967LKB/s1600/foundry+sand+mould+8.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhr0e2MwT0v4in3vMQP8p2VneevJ9WdqzuuTrV1tI-E5aXI-1Ae77FwryQT0-R3YODn9F9E-jtFj5JRfiRNMiEuwo9OcHIDpMOrCKfoIpip4lciXPqqvki6XUrjSndC1kFpFta_SY967LKB/s1600/foundry+sand+mould+8.JPG" height="100" width="150" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgdvS8mDa5FG5717kxB9OM3YDk0qrp0oXgQtL46gX1vvapyiZ3_hzZBWfxb7t922XReckWrZhbbJC8vCY2uJJLM7XjCSR5O7zL-tDhzLwaF-obTjeXqDJFekyeefOzz_WxjQiSTISHKsW_/s1600/foundry+sand+mould+9.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgdvS8mDa5FG5717kxB9OM3YDk0qrp0oXgQtL46gX1vvapyiZ3_hzZBWfxb7t922XReckWrZhbbJC8vCY2uJJLM7XjCSR5O7zL-tDhzLwaF-obTjeXqDJFekyeefOzz_WxjQiSTISHKsW_/s1600/foundry+sand+mould+9.JPG" height="100" width="150" /></a></td></tr>
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In the next set of images you can see the aluminum casting "shakeout process", in other words to open the flask and either have a nice casting surprise or a flop.....<br />
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<tr><td></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8MQxgWqeOfRioHF2EBLKIEJmtfbKhlzSOo2pLS9GHXMY3WMC07mMqBtj2kHC7JDnCfM1lMLaunjQone2JEVGYGMqyuwZ4gBueiQRUZNft8nIjP92WygSw7okaEyaPSRXRW7nWpmDUH3o9/s1600/foundry+flask+1.jpg" imageanchor="1" style="margin-left: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8MQxgWqeOfRioHF2EBLKIEJmtfbKhlzSOo2pLS9GHXMY3WMC07mMqBtj2kHC7JDnCfM1lMLaunjQone2JEVGYGMqyuwZ4gBueiQRUZNft8nIjP92WygSw7okaEyaPSRXRW7nWpmDUH3o9/s1600/foundry+flask+1.jpg" height="90" width="120" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9Ha8dDsCS0tq90N3bTFwknaDndBf-JOuFRHxtpfl4Gg_Ekw1ilo-wMD-pIN1S1YwwT6TbqLtAatBnGDC9KU9nBwg7Pgl9nVkMNAqPl9V4w5iUeNn7HcUBPNx1rZbdd5ghtVvTd0b8LxoH/s1600/foundry+flask+3.JPG" imageanchor="1" style="margin-left: 0em; margin-right: 0em;"><img alt="foundry flask after aluminum pour " border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9Ha8dDsCS0tq90N3bTFwknaDndBf-JOuFRHxtpfl4Gg_Ekw1ilo-wMD-pIN1S1YwwT6TbqLtAatBnGDC9KU9nBwg7Pgl9nVkMNAqPl9V4w5iUeNn7HcUBPNx1rZbdd5ghtVvTd0b8LxoH/s1600/foundry+flask+3.JPG" height="90" title="foundry flask" width="120" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3f9WZ8rUJT3xIpcFtBFyEpgzPWy1ZIcty5P8w49215591crLWUQIkMxmpdgrNLwhRtWxeCP9HLPzRUs8SpejtgxCZHGgTAvEfUaH0tbRVfcEtvfL9AVaXjZoqnhvkAIiS8ipcUx51UOc3/s1600/aluminum+casting+1.JPG" imageanchor="1" style="margin-left: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3f9WZ8rUJT3xIpcFtBFyEpgzPWy1ZIcty5P8w49215591crLWUQIkMxmpdgrNLwhRtWxeCP9HLPzRUs8SpejtgxCZHGgTAvEfUaH0tbRVfcEtvfL9AVaXjZoqnhvkAIiS8ipcUx51UOc3/s1600/aluminum+casting+1.JPG" height="90" width="120" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiBgRKl1yFVazjf-dkOtV87ejW5i7pO6wU6V6hr29khd1A6zegcd2JLbIPz2lmx5wLpu03viCXAm0wXQ_yHBK5LIW4BjHAZVBOah8e67rWEt2rLbhvEeUpxkHwhHUdYOaa8COB1aRG8_wQ/s1600/aluminum+casting+2.JPG" imageanchor="1" style="margin-left: 0em; margin-right: 0em;"><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiBgRKl1yFVazjf-dkOtV87ejW5i7pO6wU6V6hr29khd1A6zegcd2JLbIPz2lmx5wLpu03viCXAm0wXQ_yHBK5LIW4BjHAZVBOah8e67rWEt2rLbhvEeUpxkHwhHUdYOaa8COB1aRG8_wQ/s1600/aluminum+casting+2.JPG" height="90" title="aluminum star casting" width="120" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKZWAAYnIxs8k7IVwKMcu7PEZcredJZPTuYWzWiUpE6KdE1KUQYiYTeitP2hJOn8Za1zaL_yr23k7VhDBHf4aCq7ZxJm6S6_8snrbqVs96VI1QWiyiaHGpCklV-xpwo3XeaJjN-YPKebPt/s1600/aluminum+casting+3.JPG" imageanchor="1" style="margin-left: 0em; margin-right: 0em;"><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKZWAAYnIxs8k7IVwKMcu7PEZcredJZPTuYWzWiUpE6KdE1KUQYiYTeitP2hJOn8Za1zaL_yr23k7VhDBHf4aCq7ZxJm6S6_8snrbqVs96VI1QWiyiaHGpCklV-xpwo3XeaJjN-YPKebPt/s1600/aluminum+casting+3.JPG" height="90" title="aluminum star casting" width="120" /></a></td><td></td><td><br /></td></tr>
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Well the casting turned out very well so all that was left to do is clean all the access aluminum and give the aluminum star a semi polish finish.</div>
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<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5esMBigAZPMtlg3dUq9QzqDVFE-ldOOdD6DdO5qpCzYkmbw__3JTqTfCzwj3_7F47fNmLkPQ2UpOBXwrotb4kY7u3rBMrPXUByukTE0Q3N59ejjk3WmYHKKHx-QdIpLBPntXmBgOp0dkn/s1600/Aluminum+start+casting+with+foundry+pattern.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="aluminum star casting and foundry pattern" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5esMBigAZPMtlg3dUq9QzqDVFE-ldOOdD6DdO5qpCzYkmbw__3JTqTfCzwj3_7F47fNmLkPQ2UpOBXwrotb4kY7u3rBMrPXUByukTE0Q3N59ejjk3WmYHKKHx-QdIpLBPntXmBgOp0dkn/s1600/Aluminum+start+casting+with+foundry+pattern.JPG" height="180" title="Aluminum star casting" width="230" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK0xLR2k9Vd9I_p8OdohAcOf7y6ZmG3piHTxTaGaVemk0VPZr98b9qYhdX3rbmD1NbmPqiEspiS99A2DpyifQ-6X9mw0Icxuv1TkKhzGuJceQ7kfZh4ST93qTSfFgc50iF6Fy5GC2ipcDu/s1600/polished+aluminum+star+casting.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="Aluminum star casting using homemade foundry" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK0xLR2k9Vd9I_p8OdohAcOf7y6ZmG3piHTxTaGaVemk0VPZr98b9qYhdX3rbmD1NbmPqiEspiS99A2DpyifQ-6X9mw0Icxuv1TkKhzGuJceQ7kfZh4ST93qTSfFgc50iF6Fy5GC2ipcDu/s1600/polished+aluminum+star+casting.JPG" height="180" title="Aluminum star casting" width="230" /></a></td></tr>
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In this post I wrote a bit less then I usual do.... :-) as I have created a 2 part aluminum casting tutorial so feel free to view, like, subscribe.</center>
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<b><u><span style="color: red;">Aluminum star casting part 1 (sand mould preparation):</span></u></b></center>
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Aluminum star casting part 2 (pouring the aluminum):</center>
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<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh87Z2gXYPnO00IlKcisDBoFJtUatTx8Mxoo2YwpnwtC7TmQgr1MDKclx1mo70KKpKo40IewgmnP6VldljoUKxHO_38OQiLTm_t1ibtkjurJ8duQ9ARy9Zg5qYEHNwSe-mrtNrFmC3YIRsi/s1600/Aluminum+star,+homemade+foundry.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh87Z2gXYPnO00IlKcisDBoFJtUatTx8Mxoo2YwpnwtC7TmQgr1MDKclx1mo70KKpKo40IewgmnP6VldljoUKxHO_38OQiLTm_t1ibtkjurJ8duQ9ARy9Zg5qYEHNwSe-mrtNrFmC3YIRsi/s1600/Aluminum+star,+homemade+foundry.JPG" height="140" width="200" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEii2SthWydgpz9WYIQI5X-meqBFlksJjmSs9XNSDT4pHbPQTsSoNO7t86TEirL3cLGq9dtcJHedVlJU1l_Z8t0g4Naz0zkG2sKU_rJXybmfyx8HjljWRy6nDGkaThwkchrNgsNJ1cgZz_JK/s1600/Aluminum+star+on+tree.JPG" imageanchor="1" style="margin-left: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEii2SthWydgpz9WYIQI5X-meqBFlksJjmSs9XNSDT4pHbPQTsSoNO7t86TEirL3cLGq9dtcJHedVlJU1l_Z8t0g4Naz0zkG2sKU_rJXybmfyx8HjljWRy6nDGkaThwkchrNgsNJ1cgZz_JK/s1600/Aluminum+star+on+tree.JPG" height="140" width="200" /></a></td>
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<td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgt51yiPwKLl7bOraq6_nNc5rM4meVDgRf-fNNNLyPSQKei2V64MDRy2ZCMZlxlZ3vcXqVYAm2wUmyS95UcI1RpHiQFK3YnDcNRQNZBW7zna16QT7KGnqDcLl6xSa1CLsOT7DQXTmq6G4O7/s1600/Christmas+tree+with+aluminum+star.JPG" imageanchor="1" style="margin-left: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgt51yiPwKLl7bOraq6_nNc5rM4meVDgRf-fNNNLyPSQKei2V64MDRy2ZCMZlxlZ3vcXqVYAm2wUmyS95UcI1RpHiQFK3YnDcNRQNZBW7zna16QT7KGnqDcLl6xSa1CLsOT7DQXTmq6G4O7/s1600/Christmas+tree+with+aluminum+star.JPG" height="220" width="200" /></a></td></tr>
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FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-68952513092154735662013-07-24T14:54:00.001-07:002013-07-28T12:36:05.903-07:00Recycling aluminum cans into name plates / paper weightsIt's been a while since I posted a new project, time is very scarces these days and things I like to do are pushed aside by day to day tasks. This post is about how I turned used scrap aluminum cans into something new. My work colleagues collected aluminum drink cans for me for the last few months. I decided to make them something useful and I came up with ......Individual paper weights for each of them with their name initials on them.<br />
Unfortunately I don't have a small CNC machine, something that I hope to buy or build one day. So my second option was to make the foundry patterns from A-Z.<br />
As for the material for the patterns I decided to use 18mm MDF, and yes I know it's not a really "fun" material to work with but its easy to shape and for this type of pattern it was perfect.<br />
So first I decided what radius to make the aluminum name plates, then I made a rough cut with a jig saw around the marked radios. From a previews job I already had a perfect circle cut so I used it as a template for all the name plates.<br />
The next part was all done with my electric router, first I shaped the pattern into a perfect circle using a template and a router "Flush Trim bit", then I made another MDF Jig in order to create the pattern middle radius recess, for this job I used "Straight bit" + router collar.<br />
After I created all the pattern inner circles (the same depth as the letters 3mm) I used a "Chamfer bit" to create a decorative 45° angle on the top side of the pattern.<br />
After creating the pattern I covered the MDF with putty then sanded it to a smooth finish. After I got rid of the horrible MDF fiber texture it was smooth enough to stick to the foam letters. The last part was to give the patterns a few coats of paint and varnish. The paint and varnish really contribute to achieve a very good sand casting and aluminum casting results.<br />
This first series of images illustrates the pattern making stages:<br />
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<tr> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmdvX0L0dRuySW2qx3dJdujXu4JPnEFEJ-QAadHT_z_DZMhYqSfK-UxuG6j-gGXRK2nwDsl-rS-UT2sa-MhgZWhnJFVbcac3tWKqgoSqLiUyD2INxrkOuxlCLehyootFrRasVVixW22aqF/s1600/making+foundy+pattern+1.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry pattern" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmdvX0L0dRuySW2qx3dJdujXu4JPnEFEJ-QAadHT_z_DZMhYqSfK-UxuG6j-gGXRK2nwDsl-rS-UT2sa-MhgZWhnJFVbcac3tWKqgoSqLiUyD2INxrkOuxlCLehyootFrRasVVixW22aqF/s120/making+foundy+pattern+1.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibEWVkpENGqgyJF45iYMVrT5H1QKLiv78KZG0CIO1XuyMmU0odXjtEbD7It_S6rCjiPtZkjrhJi6WpxQH5Hhp-l8q1s4NXO9bXZCNUk7ILwfKOCPYU33hd_0xhOVY_SjsPFRrn2Id9Lzqk/s1600/making+foundy+pattern+2.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry pattern" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibEWVkpENGqgyJF45iYMVrT5H1QKLiv78KZG0CIO1XuyMmU0odXjtEbD7It_S6rCjiPtZkjrhJi6WpxQH5Hhp-l8q1s4NXO9bXZCNUk7ILwfKOCPYU33hd_0xhOVY_SjsPFRrn2Id9Lzqk/s120/making+foundy+pattern+2.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPGXmUKhAaMDhjw9Hc_Gi1SVFTDi4K1khBCAuWyBoUpiGcWN-3L7pKc1ZSP-Hbg9j_PjGscwLPqoJm0ryQWFVKEza2oPoyRUDoEXidej7SEUdDy7W4WnqUdg0fiHxDTKcYk38y8pPOSEUa/s1600/making+foundy+pattern+3.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPGXmUKhAaMDhjw9Hc_Gi1SVFTDi4K1khBCAuWyBoUpiGcWN-3L7pKc1ZSP-Hbg9j_PjGscwLPqoJm0ryQWFVKEza2oPoyRUDoEXidej7SEUdDy7W4WnqUdg0fiHxDTKcYk38y8pPOSEUa/s120/making+foundy+pattern+3.JPG" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh2KbxehcMCdGrR7dcA5y_xwHUCJYcGwzZf1bkIsrduvN-e8y4YXBaAJQt8cId8xppyJa3IkYsmMNStk7u7bERW_hF-Y9hLKaJpP32bivX6sYXy5BW6Ygx3aD-vQcSZZDoP2gDITXl1jRq/s1600/making+foundy+pattern+4.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry pattern" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh2KbxehcMCdGrR7dcA5y_xwHUCJYcGwzZf1bkIsrduvN-e8y4YXBaAJQt8cId8xppyJa3IkYsmMNStk7u7bERW_hF-Y9hLKaJpP32bivX6sYXy5BW6Ygx3aD-vQcSZZDoP2gDITXl1jRq/s120/making+foundy+pattern+4.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGQ8-uCi78jFas3SLaIBXuyjRn4YdB3AL1WKU5N954WOGg5sWcYOBVrLms2bc0f3LNooFO19MJrt3yBxPHo0En44BcKFhURA27IKpUP4VcvFqGXW92sKnOL6A-f9O6T6VhXJwwzl6hiBSN/s1600/making+foundy+pattern+5.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry pattern" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGQ8-uCi78jFas3SLaIBXuyjRn4YdB3AL1WKU5N954WOGg5sWcYOBVrLms2bc0f3LNooFO19MJrt3yBxPHo0En44BcKFhURA27IKpUP4VcvFqGXW92sKnOL6A-f9O6T6VhXJwwzl6hiBSN/s120/making+foundy+pattern+5.JPG" title="" /></a></td></tr>
</tbody></table>
<table><tbody>
<tr> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDvGMVNtzdn7TwtHNK493hwoR9kctsjAE5S1SmjQNUbngA9aHoCQ0YppnPwQMuFmZrzUiCuosggfkcEJ1hlRFRoE7bp7MaPqbhXGh0kFP-0fbdyEEOQnkbHJegtZ_A4VGMgEVEeEt5SG1Z/s1600/making+foundy+pattern+6.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry pattern" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDvGMVNtzdn7TwtHNK493hwoR9kctsjAE5S1SmjQNUbngA9aHoCQ0YppnPwQMuFmZrzUiCuosggfkcEJ1hlRFRoE7bp7MaPqbhXGh0kFP-0fbdyEEOQnkbHJegtZ_A4VGMgEVEeEt5SG1Z/s120/making+foundy+pattern+6.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUD8QQY-wLATm18egtwE5crvN5xw7HkOG7OQH2h7ABxyUve3HXz73fYSCtDB5qdfolhxZdRrVC2svW_CpCFZmuzd2joeaVmpP633xd6sghFrKbcMzYQsVN24zOXCH8_HwaYEEByYiGu4yg/s1600/making+foundy+pattern+8.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry pattern" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUD8QQY-wLATm18egtwE5crvN5xw7HkOG7OQH2h7ABxyUve3HXz73fYSCtDB5qdfolhxZdRrVC2svW_CpCFZmuzd2joeaVmpP633xd6sghFrKbcMzYQsVN24zOXCH8_HwaYEEByYiGu4yg/s120/making+foundy+pattern+8.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBE4J6N8alnSQ_vcLVD8klQRCAY8pr2iVJX7LzTl3XwJ4ngSKnhQSuClhKw2lrpzPlxYcGi-9dkVeFRBB057N5zJpSBhHGvACFsw8FcgzDBV4CauCjLOQ5M0DSEjg1f5o107YwyxBld1yE/s1600/making+foundy+pattern+9.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry pattern" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBE4J6N8alnSQ_vcLVD8klQRCAY8pr2iVJX7LzTl3XwJ4ngSKnhQSuClhKw2lrpzPlxYcGi-9dkVeFRBB057N5zJpSBhHGvACFsw8FcgzDBV4CauCjLOQ5M0DSEjg1f5o107YwyxBld1yE/s120/making+foundy+pattern+9.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHxXDvO3YkXQmyhFbceD7_DiaaOgnfcEFgqWbGZcgWiMFm1SRYWXmRhI2C_kHdDtFDMWKDC24xEHvgrsSTARkKDK2_1Yr4BgzX4lR1_f-mz94VjEBBZmo3F79ugq_0wPy_mCuZXiH9uchu/s1600/making+foundy+pattern+10.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry pattern" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHxXDvO3YkXQmyhFbceD7_DiaaOgnfcEFgqWbGZcgWiMFm1SRYWXmRhI2C_kHdDtFDMWKDC24xEHvgrsSTARkKDK2_1Yr4BgzX4lR1_f-mz94VjEBBZmo3F79ugq_0wPy_mCuZXiH9uchu/s120/making+foundy+pattern+10.JPG" title="foundry pattern" /></a></td> </tr>
</tbody></table>
After the pattern was finished I moved to the next stage, creating the sand casting cavity for the molten aluminum to fill. I used oil bonded sand for this casing to achieve a higher finishing quality. Making the sand mold was a very easy process as its just a flat pattern made from one part. When I carefully removed the pattern from the sand the sand was left with a perfect impression of the patterns.<br />
<div>
One mistake that I did was ramming the sand in the flask cope part to lightly as result there was a bit of a crack in the sand that I chose to ignore (mistake). The problem occurred when I was pouring the molten aluminum into the sand mould cavity. The molten metal lifted the sand up like a cake in the oven. What I should have done is create the cope part again or place some weight on top of the sand, that would of prevented it from rising. The casting defect that I have created is called "flash" and it could have been very easily avoided.</div>
<div>
Next set of images are from the first casting session:</div>
<table><tbody>
<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYVh0j5MFLRBS5XmZ4r4hQuhFILjyAhcWYGdBys8Cd_ZCVaNvWX_dM4-hzJp8JxhbVe9UBlyPG-OHI8_nFVmGXAxDDLQ3JJ0NDWnJzAe0_uEQnTqO2j6Tan7v8FyUtn5zYp9xpVX_GCwqh/s1600/foundry+sand+casting+1.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry sand casting" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYVh0j5MFLRBS5XmZ4r4hQuhFILjyAhcWYGdBys8Cd_ZCVaNvWX_dM4-hzJp8JxhbVe9UBlyPG-OHI8_nFVmGXAxDDLQ3JJ0NDWnJzAe0_uEQnTqO2j6Tan7v8FyUtn5zYp9xpVX_GCwqh/s120/foundry+sand+casting+1.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIfMfG7EziG-e4_Ckb7ruwWQXGuaK-IB0lrIVp8DOvs8hEaKMbXm5PUKaemo__gLzlmT7R_bnpvpE5679SeP_yMWw3YTySyatUe-eJXBV49-gbgS1ZHe-n_DkqnjvlMPwiPqB4iUaqlHGy/s1600/foundry+sand+casting+2.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry sand casting" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIfMfG7EziG-e4_Ckb7ruwWQXGuaK-IB0lrIVp8DOvs8hEaKMbXm5PUKaemo__gLzlmT7R_bnpvpE5679SeP_yMWw3YTySyatUe-eJXBV49-gbgS1ZHe-n_DkqnjvlMPwiPqB4iUaqlHGy/s120/foundry+sand+casting+2.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgX0fo0Zp050uofVSBck_aG0vn4MbHJm_nlJ_3fEmDTbxbDuDWsNYU3kqW5UxQ7sMZzbkpN_T1oIOiaZDLT6EFvX0d_una1MomN4Idz0lpL8SU5HquGnkQ8k4xxff-UfNnB7PnOc_ZdGqog/s1600/foundry+sand+casting+3.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry sand casting" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgX0fo0Zp050uofVSBck_aG0vn4MbHJm_nlJ_3fEmDTbxbDuDWsNYU3kqW5UxQ7sMZzbkpN_T1oIOiaZDLT6EFvX0d_una1MomN4Idz0lpL8SU5HquGnkQ8k4xxff-UfNnB7PnOc_ZdGqog/s120/foundry+sand+casting+3.JPG" title="" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhED_KMe3YkJytBUBisLoRtEo3Ag-iUXpXCtpy9eSNj3t8tJe0Aqsy3ibzDMmlct8eJpYEMb2_gqZMxM9cCDMgY0zc8mEaOEMBBXM_NkTyB9Wxjv1cHnEh0e3rZN8W0sredhur1PygSjmjA/s1600/first+foundry+sand+casting+failed+1.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry sand casting" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhED_KMe3YkJytBUBisLoRtEo3Ag-iUXpXCtpy9eSNj3t8tJe0Aqsy3ibzDMmlct8eJpYEMb2_gqZMxM9cCDMgY0zc8mEaOEMBBXM_NkTyB9Wxjv1cHnEh0e3rZN8W0sredhur1PygSjmjA/s120/first+foundry+sand+casting+failed+1.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhohaIH0lt_ef-1yFDHu9zwnf41kWHEmlrNrYrGzWorSn7xe5T1saB5mTXCyGKtRqXTeOJTyUaktyV7P6QgxTeAHRxca0HU3WpWJUobLsXh9RAdQluSumqf2SUiqUi6PLbmUiPgqtpsOne0/s1600/first+foundry+sand+casting+failed+2.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry sand casting" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhohaIH0lt_ef-1yFDHu9zwnf41kWHEmlrNrYrGzWorSn7xe5T1saB5mTXCyGKtRqXTeOJTyUaktyV7P6QgxTeAHRxca0HU3WpWJUobLsXh9RAdQluSumqf2SUiqUi6PLbmUiPgqtpsOne0/s120/first+foundry+sand+casting+failed+2.JPG" title="foundry aluminum sand casting" /></a></td> </tr>
</tbody></table>
I could of just left it the way it was but it was annoying me that the base side of the name plates was uneven, one side of the plates base was higher then the other side. Unfortunately I also don't have a Lathe machine and using a hand grinder was out of the question. I decided to make another sand casting this time paying more attention to details from A-Z including a better gating system using some scarp hard wood as a gating pattern.<br />
<div>
The second casting was perfect with very good casting results.</div>
<div>
Next sets of images are from the second casting session.<br />
<table><tbody>
<tr> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSZgm9LsboLOaPX2rp4lYK_YDCvvpVG16m0iQLC_oVIHzv6IVOMRUNN79dzaVkmxcudh5pKVbqNweN47FaJeE7iAFSxe8PZ1DVAGWHaUDASUTE2xPZy1yDDEf8Sxwp-EG696ReLnW_zBnv/s1600/second+aluminum+casting+2.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry sand casting" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSZgm9LsboLOaPX2rp4lYK_YDCvvpVG16m0iQLC_oVIHzv6IVOMRUNN79dzaVkmxcudh5pKVbqNweN47FaJeE7iAFSxe8PZ1DVAGWHaUDASUTE2xPZy1yDDEf8Sxwp-EG696ReLnW_zBnv/s110/second+aluminum+casting+2.JPG" title="" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpgK8AWDcQgrNpQsIn5i1SghTvXgeuYLlYgrMBfjm6aiuaunj-Y4vpeHyzlu5cE_Mj9FkQIpuneyhjoQmPn1MoLXWoUz3OnHxxoXrSVbd5DcS1d8RvLpNcrf9iK38fyho744yl6aatmNvw/s1600/seconed+alumium+casting+1.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry sand casting" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpgK8AWDcQgrNpQsIn5i1SghTvXgeuYLlYgrMBfjm6aiuaunj-Y4vpeHyzlu5cE_Mj9FkQIpuneyhjoQmPn1MoLXWoUz3OnHxxoXrSVbd5DcS1d8RvLpNcrf9iK38fyho744yl6aatmNvw/s110/seconed+alumium+casting+1.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0-hG4mSmhYpaXfgE1-dVHq2hrvZMwLT5Mco1L1Dfbdy9dZBRCDz2G3Y1qMN7wkB1iua4BWspxiK2A9pMk9tLcRRmbYenNHXi90pzntDnWX26HfzLuREdj6abX2GKplL4fV4WX_sthUXYU/s1600/second+aluminum+casting+3.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry sand casting" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0-hG4mSmhYpaXfgE1-dVHq2hrvZMwLT5Mco1L1Dfbdy9dZBRCDz2G3Y1qMN7wkB1iua4BWspxiK2A9pMk9tLcRRmbYenNHXi90pzntDnWX26HfzLuREdj6abX2GKplL4fV4WX_sthUXYU/s110/second+aluminum+casting+3.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1sp759l3Ts-pklz1pLECDkpR3A1DxI_Vh-3hxMiXxRaoQqF2DqMCkg3FZFWQA5OjLV6-iPz_u9ZOIb9MeFLlh4nUIBrYUaZgt5F5S7dsp1gZhKC98U_w6D9PPlU_hf893whodQQ4Z7ORz/s1600/second+aluminum+casting+4.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry sand casting" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1sp759l3Ts-pklz1pLECDkpR3A1DxI_Vh-3hxMiXxRaoQqF2DqMCkg3FZFWQA5OjLV6-iPz_u9ZOIb9MeFLlh4nUIBrYUaZgt5F5S7dsp1gZhKC98U_w6D9PPlU_hf893whodQQ4Z7ORz/s110/second+aluminum+casting+4.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-kTyKGnz9_ePZIrLe2h6ufE7vtYqLDI5aFbRkxz5fEZwzQ_GPOwvkKsXQef3eUSFqunPHVTywVqsI1zFBHyzpKji_B02FiCNznMsU0nZl-kf_Bj2usC93n4ebOlzMTyNvPbKBiphSU28X/s1600/second+aluminum+casting+5.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="aluminum casting" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-kTyKGnz9_ePZIrLe2h6ufE7vtYqLDI5aFbRkxz5fEZwzQ_GPOwvkKsXQef3eUSFqunPHVTywVqsI1zFBHyzpKji_B02FiCNznMsU0nZl-kf_Bj2usC93n4ebOlzMTyNvPbKBiphSU28X/s110/second+aluminum+casting+5.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNnYI40GHIRF1iLG6p2kyrfUkcSwB1NwsYoiR_ERluz7tHk6IsG-w0se1PIzHZZOcHCEi2ZzU3nhOkYxkoVH64pNW5svj-6KcCD0TOxmPGDBtTRN6LE0Tv4w3hoQbPIr5gFqE-KYfVZ8CG/s1600/second+aluminum+casting+6.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="aluminum casting" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNnYI40GHIRF1iLG6p2kyrfUkcSwB1NwsYoiR_ERluz7tHk6IsG-w0se1PIzHZZOcHCEi2ZzU3nhOkYxkoVH64pNW5svj-6KcCD0TOxmPGDBtTRN6LE0Tv4w3hoQbPIr5gFqE-KYfVZ8CG/s110/second+aluminum+casting+6.JPG" title="" /></a></td> <td></td></tr>
</tbody></table>
As this was a very good casting It didn't take me long too clean all the excess aluminum. Using metal file and electric sander I got it to a stage ready for polishing. For the polishing part one needs a lot of patience as it takes time to make it shiny. I used aluminum brown and blue buffing compound.<br />
The end result was good enough for me and I gave it as a present to my work colleagues. Now they have a fancy paper weight for their desks :-)<br />
<table><tbody>
<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2J7-pPK4_sD-qvouxEY9ygD9ABdO2X8syZ4v8Ez9GkTlD4owSrxmCw5OkIULS76ZHz9p2MUE-qV7if0m8cAujYPe9-m9KToA2nGz3sm1owJaNxMjOpabHTL6sxyOTzA9_vSYAlOlxIM5B/s1600/aluminum+casting+and+patterns.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="aluminum casting" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2J7-pPK4_sD-qvouxEY9ygD9ABdO2X8syZ4v8Ez9GkTlD4owSrxmCw5OkIULS76ZHz9p2MUE-qV7if0m8cAujYPe9-m9KToA2nGz3sm1owJaNxMjOpabHTL6sxyOTzA9_vSYAlOlxIM5B/s135/aluminum+casting+and+patterns.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgewGgayNTVovtaXwe8xENvKIZqBxy12moge0MBfDsfFgqrmXKhIKkzGxR5NaOwQbxKcokYf5HsOXSGlz5GP6mb8YuFmktQuTkc_gIWiMe5IU0vzIlsvJhkTxc_SNRVq5HsyCFXX8YFQCUt/s1600/aluminum+casting+polish.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="aluminum polish" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgewGgayNTVovtaXwe8xENvKIZqBxy12moge0MBfDsfFgqrmXKhIKkzGxR5NaOwQbxKcokYf5HsOXSGlz5GP6mb8YuFmktQuTkc_gIWiMe5IU0vzIlsvJhkTxc_SNRVq5HsyCFXX8YFQCUt/s135/aluminum+casting+polish.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhj049TTAZkYIJsKg3cIU9itC6sh9-BNn6ysC__BACsni1Ih5RmIwNpIg5L89vx1e3EmBZwKZDpuW0xH9M11ZIysF2jgwG0ibVYaouVcVQ48YfUi6S6FAkn2bvc3KvA_-8OMrFGr-qY9Wyv/s1600/aluminum+name+plate+casting+and+pattern.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="aluminum casting" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhj049TTAZkYIJsKg3cIU9itC6sh9-BNn6ysC__BACsni1Ih5RmIwNpIg5L89vx1e3EmBZwKZDpuW0xH9M11ZIysF2jgwG0ibVYaouVcVQ48YfUi6S6FAkn2bvc3KvA_-8OMrFGr-qY9Wyv/s135/aluminum+name+plate+casting+and+pattern.JPG" title="" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5Y3kim974fw7DK78MEN0yayOBDo8e6OjTnAcfcZVjQ3XV385mNJHoqu9qAGpinagqAPUQ3uqz-o_NPMoN6a7Cq1uB62hXK0egHeaer4U8zkrMd60uKKm87hVJZg6m2aSIX5A2JsqrULl7/s1600/finished+aluminum+casting+name+plate.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="aluminum casting" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5Y3kim974fw7DK78MEN0yayOBDo8e6OjTnAcfcZVjQ3XV385mNJHoqu9qAGpinagqAPUQ3uqz-o_NPMoN6a7Cq1uB62hXK0egHeaer4U8zkrMd60uKKm87hVJZg6m2aSIX5A2JsqrULl7/s170/finished+aluminum+casting+name+plate.JPG" title="homemade aluminum foundry casting" /></a></td></tr>
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This is a short video that I made of the aluminum name plates, creation stages:</div>
<iframe allowfullscreen="" frameborder="0" height="315" src="//www.youtube.com/embed/h2l9TCdZfX8?rel=0" width="420"></iframe>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-21682864995211371962013-03-21T13:55:00.001-07:002013-08-12T12:34:23.307-07:00Scrap Aluminum for the Homemade FoundryIn my previous posts I went over<a href="http://www.flamingfurnace.com/2012/11/foundry-setup-crucible-flask-and.html" target="_blank"> how to setup a homemade aluminum foundry.</a> This post will be dedicated to the subject of what scrap aluminum would be ideal for the homemade foundry. At this stage I have melted many aluminum alloys from different objects.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBbEOqXKbhxsg60rhjqlQKn3b5i2MLBaegva6rL4ZqzXSORmiEv3cUCje7MTZKkmaxmiVqX977W99o9gxVYGj-uWXd3B8HdV3A3d9GWLDixylSMHTz7otbtTwWovQ4Cu3_rSMxvh5IDfVW/s1600/Scrap+aluminum+for+the+homemade+foundry.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 1em;"><img alt="scrap aluminum for the homemade foundry" border="0" height="160" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBbEOqXKbhxsg60rhjqlQKn3b5i2MLBaegva6rL4ZqzXSORmiEv3cUCje7MTZKkmaxmiVqX977W99o9gxVYGj-uWXd3B8HdV3A3d9GWLDixylSMHTz7otbtTwWovQ4Cu3_rSMxvh5IDfVW/s200/Scrap+aluminum+for+the+homemade+foundry.JPG" title="" width="200" /></a></div>
One of the main things that makes this odd hobby fun is taking used aluminum items and recycling them into something new, for example the <a href="http://www.flamingfurnace.com/2013/01/foundry-sand-casting-project-for-my.html" target="_blank">decorative animal shapes</a> that I made for my kids room I made from an old<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuoa2gR1XoH7iYb1auNp9GYS9HCivpepaR3XPzffQPn_1HkPwhq2fzr_2CLMTb5f_53Qhx0lp7VsngoPtkQdGOhbsvWoOwtJlcJiuN_Y4SRhLmCUiC5t-ZNokoboAvnmVx_mwLyGfjcG_h/s1600/recycling+aluminum+into+something+new.PNG" target="_blank"> pressure cooker</a>. Its very easy to order online ready processed aluminum ingots however I think it takes away from the fun of looking for scrap parts and processing them from scratch into something new. There are many types of aluminum objects made from different alloys that can be used by the amateur metal caster. On the image at the left you can see different types of objects that I melted into clean aluminum ingots. For example an aluminum scooter, brackets, pressure cooker lid, baby pram frame, flood light frame, electric box cover, door handles, solid aluminum engine block, ladder parts, engine piston and old antenna tubes. Another point to rise is that for many metal casting hobbyists there is no need really to segregate the aluminum alloys for a simple reason, not too many people are casting in their back yard, Aluminum parts such as engine pistons that requires unique grade of alloys because of the unique mechanical purpose of the object. Most homemade foundry metal casters that are doing it for a hobby will usually create decorative objects that will sit on the shelf or be hung on the wall that's why it doesn't really matter the alloy segregation. However after saying that it is a good practice to make the metal casting from the same alloy if possible.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhI88tozTakd1pf7-Ti4TyVtNW-jD5WxH8bLvHcnk8Dx0TbzVol9o8u9QFGGJdejUd1ck9nIHJYi8Jl0yfPXhCcDn2v4NESuatby9MK9VwTKhvlWj-VYDX8pkiVvBjBH_p_rTiGxVLMaVAK/s1600/cuting+aluminum+engine+block+into+4+parts.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img alt="cutting aluminum engine block into 4 parts before melting it" border="0" height="200" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhI88tozTakd1pf7-Ti4TyVtNW-jD5WxH8bLvHcnk8Dx0TbzVol9o8u9QFGGJdejUd1ck9nIHJYi8Jl0yfPXhCcDn2v4NESuatby9MK9VwTKhvlWj-VYDX8pkiVvBjBH_p_rTiGxVLMaVAK/s200/cuting+aluminum+engine+block+into+4+parts.JPG" title="" width="110" /></a></div>
What I can recommend as a good source of aluminum is car engine parts. I got from a friend a broken engine block. My main problem is that my foundry and crucible are too small for such a big part of aluminum. I started by taking a heavy hammer and breaking all of the engine block edges, after I cut it into 4 chunks of aluminum that would fit into my crucible. I got a fair amount of aluminum from this aluminum engine block. All the metal parts pose no issue as once the aluminum turns molten its very easy just too scoop them out before pouring the molten aluminum into the ingot mold.<br />
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One source of aluminum I wouldn't really recommend to collect and melt is aluminum tubing. The volume of aluminum to be extracted is very low and the time consumption of the melting session is just not worth it.<br />
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<tr><td></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBSZfMROe1Gbvdf0TkW7ZXpTL9J6MP3c-D-tv_rF0NWH915G4esinwq68l1PXuQOLbNLN1hlu15eR4pd3XAOp6WNWFreIgP0PSTx59UVRdnW96TXPZSzFgy8Pp5noQEo_LBqB3aZ7LRWGL/s1600/breaking+aluminum+engine+block.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="breaking aluminum engine block" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBSZfMROe1Gbvdf0TkW7ZXpTL9J6MP3c-D-tv_rF0NWH915G4esinwq68l1PXuQOLbNLN1hlu15eR4pd3XAOp6WNWFreIgP0PSTx59UVRdnW96TXPZSzFgy8Pp5noQEo_LBqB3aZ7LRWGL/s200/breaking+aluminum+engine+block.JPG" title="" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtTutqbvrIbMl7BSkNAKJ2vOHQ4kbTYjPhCDZEXS4J5XkmqLGempTq08_JsZrIpEEKhj5sHr5SevrwCqJe_vFeWvk1uA_NmuIxR93YNLP6-8adHqeB_6Cw1TZTvvX1dtKOugy2njKSeAoR/s1600/aluminum+engine+block+cut+into+4+parts.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="aluminum engine block cut into 4 parts" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtTutqbvrIbMl7BSkNAKJ2vOHQ4kbTYjPhCDZEXS4J5XkmqLGempTq08_JsZrIpEEKhj5sHr5SevrwCqJe_vFeWvk1uA_NmuIxR93YNLP6-8adHqeB_6Cw1TZTvvX1dtKOugy2njKSeAoR/s200/aluminum+engine+block+cut+into+4+parts.jpg" title="" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3iUNnj9JWRS9x7nL68MvkjOrnBmxl8SWKal5-adl-2Hg8kQZEboSt6E4RG-hBfovYNjVLpsRDmfrLa7c-xJkvsdi_VvkygT2inA_FiP7fTwT_TcR7G5t0WtxsFjo2sGb3ekg5GT7sNfwp/s1600/aluminum+scrap+in+crucible.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em; text-align: center;"><img alt="aluminum scrap in crucible" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3iUNnj9JWRS9x7nL68MvkjOrnBmxl8SWKal5-adl-2Hg8kQZEboSt6E4RG-hBfovYNjVLpsRDmfrLa7c-xJkvsdi_VvkygT2inA_FiP7fTwT_TcR7G5t0WtxsFjo2sGb3ekg5GT7sNfwp/s200/aluminum+scrap+in+crucible.jpg" title="" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnhlZ69ZcKAThtNWYwmxRzRpb3-qCEoIPkXWTO4_21YMsleELWLmrkbjsKIWCJZlAWqGecr2J8D2G3y0nu9eEk6hks4xMVIxmOXFmqc7JEuO9O9MqtQiBBdC0ftvW3X6yx4V9pcRnkbcKn/s1600/engine+block+scrap+in+crucible.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="engine block scrap in crucible" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnhlZ69ZcKAThtNWYwmxRzRpb3-qCEoIPkXWTO4_21YMsleELWLmrkbjsKIWCJZlAWqGecr2J8D2G3y0nu9eEk6hks4xMVIxmOXFmqc7JEuO9O9MqtQiBBdC0ftvW3X6yx4V9pcRnkbcKn/s200/engine+block+scrap+in+crucible.jpg" title="" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNIEZPrExkjVN3mVW4YlfVCAJcSsRzyF_mbw-9zntSYAWEicYiWD-y_aOo7pyYwovfYLudD3uWpidURo5yGedcffZUsXR6PmSD_BoFP-aEk22tv3z_87WSGsn-EqJ2qEgYaiZgNl1njvLB/s1600/aluminum+ingots+and+engine+block+metal+scrap.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="aluminum ingots and engine block metal scrap" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNIEZPrExkjVN3mVW4YlfVCAJcSsRzyF_mbw-9zntSYAWEicYiWD-y_aOo7pyYwovfYLudD3uWpidURo5yGedcffZUsXR6PmSD_BoFP-aEk22tv3z_87WSGsn-EqJ2qEgYaiZgNl1njvLB/s200/aluminum+ingots+and+engine+block+metal+scrap.jpg" title="" width="120" /></a></td><td><br />
<br /></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3iUNnj9JWRS9x7nL68MvkjOrnBmxl8SWKal5-adl-2Hg8kQZEboSt6E4RG-hBfovYNjVLpsRDmfrLa7c-xJkvsdi_VvkygT2inA_FiP7fTwT_TcR7G5t0WtxsFjo2sGb3ekg5GT7sNfwp/s1600/aluminum+scrap+in+crucible.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><br />
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When running a homemade foundry it's always good practice to make the sand mold first and after to light up the foundry melting clean ingots. Using clean ingots may increase the odds of a good aluminum <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html" target="_blank">sand casting</a> without the need too skim too much impurities out of the molten metal in the middle of the session. Also working with clean ingots will dramatically decrease casting defects. In the next images you can see an example of an old flood light, broken aluminum light frame and after skimming all the impurities and pouring the clean aluminum into ingots. The ugly blob of <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html" target="_blank">dross </a>is all the impurities such as old paint and dirt.<br />
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<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCOBSJLwcyjhldie0A52yxb7Au42gljHNkOcrCLKO1-RxRBYc4O3E-O5V5wTC9IbjrqcKM3YUGLrQzVvrmPm1akU7Ph4GUoJzJ4ovtv1274BeKYRBipSvbbl38fj-4Sijb7Myce8_BTMEh/s1600/aluminum+scrap+in+foundry+crucible.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="aluminum scrap in foundry crucible" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCOBSJLwcyjhldie0A52yxb7Au42gljHNkOcrCLKO1-RxRBYc4O3E-O5V5wTC9IbjrqcKM3YUGLrQzVvrmPm1akU7Ph4GUoJzJ4ovtv1274BeKYRBipSvbbl38fj-4Sijb7Myce8_BTMEh/s200/aluminum+scrap+in+foundry+crucible.jpg" title="" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyMAjRPAAigyqAvD-dFCVVr7VkuW6ijJuj9prIZmb_W0ae7Jmgpm9RcU1gs3LmXg_QWcLPrjWo8Ch0zzhSYuSQ-5F99MZm-5C1SaTuh85T0px0KIOsnW-ZlWQfhyphenhyphen4zaKc7IhHtkfX96wjG/s1600/cutting+aluminum+tubes.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="cutting aluminum tubes" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyMAjRPAAigyqAvD-dFCVVr7VkuW6ijJuj9prIZmb_W0ae7Jmgpm9RcU1gs3LmXg_QWcLPrjWo8Ch0zzhSYuSQ-5F99MZm-5C1SaTuh85T0px0KIOsnW-ZlWQfhyphenhyphen4zaKc7IhHtkfX96wjG/s200/cutting+aluminum+tubes.jpg" title="" width="120" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJfU8ExCXBLcGvCVXUF3EOUokqT9zs6NW1SM0glTNTYy2hwIkohtSHR4mQUZ_UpThZrEYKZdRfsZF_FtQt-iEo6ulcLvhXpTnAVVl65a7dvnuVnB0gfP_UyNzvfoAJq-2TfKvuQ8vwlrdy/s1600/recycling+aluminum+in+a+homemade+foundry.JPG" imageanchor="1" style="margin-left: 0em; margin-right: 0em;"><img alt="recycling aluminum in a homemade foundry" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJfU8ExCXBLcGvCVXUF3EOUokqT9zs6NW1SM0glTNTYy2hwIkohtSHR4mQUZ_UpThZrEYKZdRfsZF_FtQt-iEo6ulcLvhXpTnAVVl65a7dvnuVnB0gfP_UyNzvfoAJq-2TfKvuQ8vwlrdy/s200/recycling+aluminum+in+a+homemade+foundry.JPG" title="recycling aluminum scrap" width="120" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBzXi2ZjhK1HfB7Smoi__snWKpQ9w6tzJxwJm6XapWMLicbl7KQPa1MrHCBnbV8WnchZKZcck0xliRN6I-5oLlHJcpN-0qvd1a4FqYRUwv3JeX40JLAsdpI7XS6YLcbTdgaQ1KFmAIaGco/s1600/homemade+foundry+aluminum+dross.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><br />
</a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkEMtzjzuMoHYf7RmuqF6A9clMo2OvMcuC4Re4zHAb4SWZcZ1FKMwFZX0vRFqpSaCTNQPpbHGStZbQZEXnkNAyLTh8jwIhPwq6-xgYRBQUEP5jUHt8BSfGMm3V1JNCGMujnNFcQq2sLWlI/s1600/removed+from+foundry+crucible+engine+block+metal+scrap.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="removed from foundry crucible engine block metal scrap" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkEMtzjzuMoHYf7RmuqF6A9clMo2OvMcuC4Re4zHAb4SWZcZ1FKMwFZX0vRFqpSaCTNQPpbHGStZbQZEXnkNAyLTh8jwIhPwq6-xgYRBQUEP5jUHt8BSfGMm3V1JNCGMujnNFcQq2sLWlI/s200/removed+from+foundry+crucible+engine+block+metal+scrap.jpg" title="scrap metal" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPsebzClVILV2CxLFTXpHnMurz1Ex1vfOq1dvEOJLL4czp7WjcHZLLLQALgNV4R-rm3lOMj5QLCnRZWGP7j-PtT8bE-BStlwLgVZw3nfZ-Z3f0Y_5LglL-2kXMcstc74TRGmXx19VIwA3P/s1600/aluminum+ingot+pile.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em; text-align: center;"><img alt="aluminum ingot pile" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPsebzClVILV2CxLFTXpHnMurz1Ex1vfOq1dvEOJLL4czp7WjcHZLLLQALgNV4R-rm3lOMj5QLCnRZWGP7j-PtT8bE-BStlwLgVZw3nfZ-Z3f0Y_5LglL-2kXMcstc74TRGmXx19VIwA3P/s200/aluminum+ingot+pile.jpg" title="aluminum ingots" width="120" /></a></td></tr>
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The next thing I decided to try is an experiment on how much aluminum I can extract from melting drink cans. I know I don't recommend it in my site safety statement but again this is for educational purpose ;-) I started by making a primitive can crusher by welding some scrap metal. The more compacted the cans are the less space they take in the crucible and it is quicker feeding them into the <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html" target="_blank">crucible</a>. For my drink cans melting experiment I collected <b>2.5 K.G</b> of aluminum drink cans. Melting cans is a very quick and easy process once the foundry reaches the adequate temperature. The down side is too much impurities that needs to be skimmed out from the top of the molten metal, very frequently.<br />
I got a total of <b>1.5-KG</b> aluminum and <b>1-K.G</b> Dross (scrap impurities).<br />
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<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDVX2O23duKVeRoEF6Av6AXQff17opG_m5VmsZrpEpMo9Uy2GT_suRbhG3S4UNR-9xyBRJ4bTxoFvwqjxXiyd_db7nwjck5DTBM0biqbGId1uU8DWi9SsxCPKtn2oaT-J7OmMABfTUEQnt/s1600/drink+can+crusher.JPG" imageanchor="1" style="margin-left: 0em; margin-right: 0em;"><img alt="drink can crusher" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDVX2O23duKVeRoEF6Av6AXQff17opG_m5VmsZrpEpMo9Uy2GT_suRbhG3S4UNR-9xyBRJ4bTxoFvwqjxXiyd_db7nwjck5DTBM0biqbGId1uU8DWi9SsxCPKtn2oaT-J7OmMABfTUEQnt/s200/drink+can+crusher.JPG" title="recycling aluminum cans" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi74k0IFsfuLczB6fydb4VzbM2HF6tx_wW-jI2u6BvB-nwsk7Fwcp2bZK-2j5utQmA5bGjsWW-Bvfs_y8KyN3vEEt31JrkvntDSMG_mNpU-KrgfR7csIKqMpLvR78Lwuw6VEypnzkjgMEYb/s1600/drink+cans+to+be+melted+in+the+crucible.JPG" imageanchor="1" style="margin-left: 0em; margin-right: 0em;"><img alt="recycling aluminum cans" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi74k0IFsfuLczB6fydb4VzbM2HF6tx_wW-jI2u6BvB-nwsk7Fwcp2bZK-2j5utQmA5bGjsWW-Bvfs_y8KyN3vEEt31JrkvntDSMG_mNpU-KrgfR7csIKqMpLvR78Lwuw6VEypnzkjgMEYb/s200/drink+cans+to+be+melted+in+the+crucible.JPG" title="recycling aluminum cans" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwdpIEgBQFN4OfsHyhSV3WXj-1WosgYg-vqd68udZKoXzLFH0YvQ7jtjWVi35VSXvNIAXZZBivlHdnq27JnJ_eehMFeDpZSHhEtgXuo2ARL8jYWOXyK4zWNlKA0BfhjT0kvElbOQ7eNjRY/s1600/2.5KG+aluminum+cans+into+1.5KG-ingots++1KG-dross+(Small).JPG" imageanchor="1" style="margin-left: 0em; margin-right: 0em;"><img alt="2.5KG aluminum cans into 1.5KG-ingots 1KG-dross " border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwdpIEgBQFN4OfsHyhSV3WXj-1WosgYg-vqd68udZKoXzLFH0YvQ7jtjWVi35VSXvNIAXZZBivlHdnq27JnJ_eehMFeDpZSHhEtgXuo2ARL8jYWOXyK4zWNlKA0BfhjT0kvElbOQ7eNjRY/s200/2.5KG+aluminum+cans+into+1.5KG-ingots++1KG-dross+(Small).JPG" title="recycling aluminum cans into aluminum ingots" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBzXi2ZjhK1HfB7Smoi__snWKpQ9w6tzJxwJm6XapWMLicbl7KQPa1MrHCBnbV8WnchZKZcck0xliRN6I-5oLlHJcpN-0qvd1a4FqYRUwv3JeX40JLAsdpI7XS6YLcbTdgaQ1KFmAIaGco/s1600/homemade+foundry+aluminum+dross.jpg" imageanchor="1" style="clear: left; margin-bottom: 0em; margin-right: 0em;"><img alt="homemade foundry aluminum dross" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBzXi2ZjhK1HfB7Smoi__snWKpQ9w6tzJxwJm6XapWMLicbl7KQPa1MrHCBnbV8WnchZKZcck0xliRN6I-5oLlHJcpN-0qvd1a4FqYRUwv3JeX40JLAsdpI7XS6YLcbTdgaQ1KFmAIaGco/s200/homemade+foundry+aluminum+dross.jpg" title="Dross from recycling aluminum cans" width="120" /></a></td></tr>
</tbody></table>
FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-33389454898368932162013-02-23T13:47:00.000-08:002013-04-16T03:49:41.691-07:00Casting aluminum pistol and suppressor replicaLast weekend I had a few spare hours so I decided to create a solid aluminum pistol replica with an attachable suppressor. I bought a cheap plastic toy pistol from a 1$ shop, first I carefully separated the pistol into 2 halves trying not to break the plastic casting. After I had the 2 parts separated I filed off the extra bits that might ruin the sand mold. I left 4 plastic pins in one part of the pistol pattern that way the two part would align perfectly. I decided to attach a suppressor to the pistol so I made another sand mold using a separate foundry flask. I also used hard plastic tube (vitamin-c sweets tube) as a pattern for the aluminum casting. For both sand molds I used my green molding sand I was surprised that I didn't have to add water to the sand mixture, it was still good for use since I store the green sand in a closed plastic box.<br />
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<tr><td><br /></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVtq8xdMTCn_rqHeQeLtiNtCLeRjbZrNTuBNoO8Jj0m7L71j0QJk685ATBQEaIHEDBKUOlLpXDO0FW-znQR8IOmUB10jKYq5vwYQQm8_0PI6c0-lSB20uSvCVW_CPxY73oYggMJ9oTJhW7/s1600/foundry+sand+casting+cope+part.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em; text-align: center;"><img alt="foundry sand casting aluminum pistol replica" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVtq8xdMTCn_rqHeQeLtiNtCLeRjbZrNTuBNoO8Jj0m7L71j0QJk685ATBQEaIHEDBKUOlLpXDO0FW-znQR8IOmUB10jKYq5vwYQQm8_0PI6c0-lSB20uSvCVW_CPxY73oYggMJ9oTJhW7/s200/foundry+sand+casting+cope+part.JPG" title="foundry sand casting" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFcSC2HpdjTfUa9UZ8EGyxtUk_nyVN_aHVUBZ80tN85rNeKGhFJR6o2H4O0WmwQRTGysUyDlDUBzczbMBxvvMU9H8hm_0YDFUHVppyVQNeckfUtvbSoHJD5npIR7a6qMA0Qd6TPgMkvK7_/s1600/foundry+sand+casting+cope+and+drag.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="foundry sand casting cope and drag" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFcSC2HpdjTfUa9UZ8EGyxtUk_nyVN_aHVUBZ80tN85rNeKGhFJR6o2H4O0WmwQRTGysUyDlDUBzczbMBxvvMU9H8hm_0YDFUHVppyVQNeckfUtvbSoHJD5npIR7a6qMA0Qd6TPgMkvK7_/s200/foundry+sand+casting+cope+and+drag.JPG" title="foundry flask cope and drag" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOTZW_2xs51ZErtkVO24dHwcFhRGtkBs_DxOPb15Xx1atXYmDB4AZJ0UZaYYRBRrvRAYgfelMW-hiEktK0J9-Vs9c5ULXaI5K6XBw8G_9f5u6udYRWdE4jJtRz8nEvs7RvqepccxAcXs3P/s1600/foundry+sand+casting+sprue+and+riser.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="sand casting foundry flask cope" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOTZW_2xs51ZErtkVO24dHwcFhRGtkBs_DxOPb15Xx1atXYmDB4AZJ0UZaYYRBRrvRAYgfelMW-hiEktK0J9-Vs9c5ULXaI5K6XBw8G_9f5u6udYRWdE4jJtRz8nEvs7RvqepccxAcXs3P/s200/foundry+sand+casting+sprue+and+riser.JPG" title="flask cope part" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyaSMlUC4Bv564XurUL4TkXG7cqUiiw-mr_FNkJu5O8zAgJtbEkfKVS6duNph5jZroOXvdzHfisfmCId_W4nkeqqTM3Bsxb4FVD5aASQJlRA-Ro0qqSxhGYHDScKn2L5WFT1Smj1YltjJX/s1600/sand+casting+cope+and+drag+ready+for+aluminum+casting.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="sand casting gating system" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyaSMlUC4Bv564XurUL4TkXG7cqUiiw-mr_FNkJu5O8zAgJtbEkfKVS6duNph5jZroOXvdzHfisfmCId_W4nkeqqTM3Bsxb4FVD5aASQJlRA-Ro0qqSxhGYHDScKn2L5WFT1Smj1YltjJX/s200/sand+casting+cope+and+drag+ready+for+aluminum+casting.JPG" title="foundry sand casting" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZmkSMgV59W3yWOZnbbbb1DN3eW1hECMF858tmtps59G4kt7s50w3XC0fPcsCJTDC7lmD_4Gno1zhOwvGovR7b_ME6NgXtL1vM5KP6RZDFel7TisP79QXJD8GAiOCsg-HucSDAIbeJAzCi/s1600/sand+casting+aluminum+pistol+suppressor.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="sand casting suppressor mould" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZmkSMgV59W3yWOZnbbbb1DN3eW1hECMF858tmtps59G4kt7s50w3XC0fPcsCJTDC7lmD_4Gno1zhOwvGovR7b_ME6NgXtL1vM5KP6RZDFel7TisP79QXJD8GAiOCsg-HucSDAIbeJAzCi/s200/sand+casting+aluminum+pistol+suppressor.JPG" title="" width="120" /></a></td></tr>
</tbody></table>
After finishing the sand mold and the gating system for the molten aluminum I secured the foundry flask cope and drag with clamps. The casting session was quick for this project as there was no need for a big amount of aluminum for such a small casting. Half a crucible of molten aluminum was enough for the pistol replica and the suppressor. I poured the molten aluminum into the sand mold cavity and let the casting cool down for half an hour. The casting was not bad at all, not as high a quality finish as you would get using oil bonded sand (Petrobond) but good enough for homemade green sand. After the metal cooled down I used a reciprocating saw to cut off the gating system.<br />
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<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjt1kt6E44sYjagG0obFcbJwL-MuHCeoEn2ttsqVuPD4-mohkNgbmjnFYUMrpbEzr21Fy4l3IQ0YCLY7mLh00Uvs1xXFEnNQ8NU2D9EfLCct2G_eKBQjOJrnO2G6g1OCRcKYds36ToodQEI/s1600/aluminum+pistol+casting+shakeout+greensand.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em; text-align: center;"><img alt="aluminum pistol casting green sand " border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjt1kt6E44sYjagG0obFcbJwL-MuHCeoEn2ttsqVuPD4-mohkNgbmjnFYUMrpbEzr21Fy4l3IQ0YCLY7mLh00Uvs1xXFEnNQ8NU2D9EfLCct2G_eKBQjOJrnO2G6g1OCRcKYds36ToodQEI/s200/aluminum+pistol+casting+shakeout+greensand.JPG" title="green sand shake out" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVXm-TA3seJ7HZ7BlZNLWNkZ-PYDNNTPCOShK2WoiAVTWiScyT7CTQ6YPkZvgXEvs662EbSOXHd06fWjuA0NpcZZiJuXiJYCB60SxCP9xKdc-ICLTXsj3R_ow2zFeZE9nD7H9jmuWguVJn/s1600/aluminum+pistol+suppressor+removed+from+casting+greensand.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em; text-align: center;"><img alt="aluminum suppressor casting " border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVXm-TA3seJ7HZ7BlZNLWNkZ-PYDNNTPCOShK2WoiAVTWiScyT7CTQ6YPkZvgXEvs662EbSOXHd06fWjuA0NpcZZiJuXiJYCB60SxCP9xKdc-ICLTXsj3R_ow2zFeZE9nD7H9jmuWguVJn/s200/aluminum+pistol+suppressor+removed+from+casting+greensand.JPG" title="suppressor casting" width="120" /></a></td> <td><div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnUhq095CKQ49zGY-Y-SDxQ3YHwjhgf1csCZqfbIThynRJSaGusjoPQ3qB7w1Mel5ap5i8d9pHzaun6pOoF84k0fGgzBkuEbuuP2YhwgaPX6FlPGhrg5yX3KI1PuHycU3qqGqoDE6rFRbZ/s1600/aluminum+pistol+casting+before+cutting+sprue+and+riser.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="aluminum pistol casting with sprue and riser" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnUhq095CKQ49zGY-Y-SDxQ3YHwjhgf1csCZqfbIThynRJSaGusjoPQ3qB7w1Mel5ap5i8d9pHzaun6pOoF84k0fGgzBkuEbuuP2YhwgaPX6FlPGhrg5yX3KI1PuHycU3qqGqoDE6rFRbZ/s200/aluminum+pistol+casting+before+cutting+sprue+and+riser.JPG" title="aluminum pistol replica" width="120" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGd6Ge0i-DeulNuUnbS8t3ZceDZ7-dZOEb9EFs-lMS88cqGs6PPTjgP8iUwCxSB63_NYAQH9Dv7fQL6INKfntAFScYN1Txd2mPtPrTRRdvIc0BIPabbRbmW64WYmcbsE8i5o2nNYCWApUh/s1600/aluminum+pistol+casting+with+sprue+and+riser.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="solid aluminum pistol casting replica" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGd6Ge0i-DeulNuUnbS8t3ZceDZ7-dZOEb9EFs-lMS88cqGs6PPTjgP8iUwCxSB63_NYAQH9Dv7fQL6INKfntAFScYN1Txd2mPtPrTRRdvIc0BIPabbRbmW64WYmcbsE8i5o2nNYCWApUh/s200/aluminum+pistol+casting+with+sprue+and+riser.JPG" title="" width="120" /></a></div>
</td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5APgiHqGd96CGVEHNBvfpJ3tAz9zZh_WWr3QwnSCJZr_bS9Ldnjzh7YW0KV8UiYSrgOwmJSq-CzkdpyD4tqFtTd0U0MysmbhqPu2NcuYasQPN-JqEUnS5IjrGcqKwRae7wK2HhpAC-1x5/s1600/aluminum+pistol+casting+after+removing+gating+system.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em; text-align: center;"><img alt="cutting sprue and riser" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5APgiHqGd96CGVEHNBvfpJ3tAz9zZh_WWr3QwnSCJZr_bS9Ldnjzh7YW0KV8UiYSrgOwmJSq-CzkdpyD4tqFtTd0U0MysmbhqPu2NcuYasQPN-JqEUnS5IjrGcqKwRae7wK2HhpAC-1x5/s200/aluminum+pistol+casting+after+removing+gating+system.JPG" title="cutting sprue and riser from aluminum casting" width="120" /></a></td></tr>
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The next stage was to file clean all the extra aluminum "flash", the casting was good so the cleaning part didn't take too long. After filing the extra aluminum I sanded the aluminum pistol replica and the suppressor. I used my tap and die set to create the threaded holes and a small two sided bolt to secure the suppressor to the pistol barrel. The polishing part is where I never really have too much patience, especially if it is a large object with odd angles. I decided to semi polish the pistol replica giving it a bit more of an authentic look. The suppressor part I polished with more patience ;-)<br />
<table><tbody>
<tr><td tr=""><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0GQbLrO7YLc0jZwcNnSIyUtEjqiYdEpb1TQjIhCNeA4s6wir_MpiVYriwg7VDqC3WmxIYXMBk-tYZyso1pVDWkwohb3At-6cj63HfNzvLyLJ1M56zY6SRBFAxd0j7eCcn998f1HqRJ7X7/s1600/cutting+aluminum+riser.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em; text-align: center;"><img border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0GQbLrO7YLc0jZwcNnSIyUtEjqiYdEpb1TQjIhCNeA4s6wir_MpiVYriwg7VDqC3WmxIYXMBk-tYZyso1pVDWkwohb3At-6cj63HfNzvLyLJ1M56zY6SRBFAxd0j7eCcn998f1HqRJ7X7/s200/cutting+aluminum+riser.JPG" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiELcT6I5Fmgtb3soeDrw2-gkcQoFxk-R1WDF8p4MxDgm4Dg1ehBswBeEG-4XYBDeuJIzodwIvJl-auojgZWR5Ju1Or2lSP3WgJTuETWmRREgxefCkcd6CZxtemBpnqGC22cgoYjzkBjtBU/s1600/creating+the+threaded+hole+in+the+aluminum+pistol+replica.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="threading aluminum casting" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiELcT6I5Fmgtb3soeDrw2-gkcQoFxk-R1WDF8p4MxDgm4Dg1ehBswBeEG-4XYBDeuJIzodwIvJl-auojgZWR5Ju1Or2lSP3WgJTuETWmRREgxefCkcd6CZxtemBpnqGC22cgoYjzkBjtBU/s200/creating+the+threaded+hole+in+the+aluminum+pistol+replica.JPG" title="using tap and die set to make threaded hole " width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhg0m_Me2cz9NLagrlChLJmnEvD6FL_zHW6xKRS-KWNaRWk3aGKfSuYwXRnR2vRl0cPbd2M2Bp7SivN67wg2-_JcGL3EkFx_KdA5Ub4N_KATh6Ez9k0G3-0TYL5KTe6rtayvcutd6XslM3E/s1600/aluminum+polish.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="polishing aluminum casting" border="0" height="=75" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhg0m_Me2cz9NLagrlChLJmnEvD6FL_zHW6xKRS-KWNaRWk3aGKfSuYwXRnR2vRl0cPbd2M2Bp7SivN67wg2-_JcGL3EkFx_KdA5Ub4N_KATh6Ez9k0G3-0TYL5KTe6rtayvcutd6XslM3E/s200/aluminum+polish.JPG" title="polishing aluminum" width="110" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgL7nBoUWGBu2MxXiQzAWf4xHQTMwgPLYQ__f2_qRjJH9hIECso-ZA9FSbI3N6IuTogdluz95s8Vrd5om7r27QBG2Y6oAzIxwzw6PwweN3t6x94k0uMLGDdfUO6vJFW6rEr-NFMp9w_h0GO/s1600/aluminum+pistol+replica+with+suppressor+attached.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 0em; margin-right: 0em;"><img alt="homemade foundry, aluminum sand casting pistol replica " border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgL7nBoUWGBu2MxXiQzAWf4xHQTMwgPLYQ__f2_qRjJH9hIECso-ZA9FSbI3N6IuTogdluz95s8Vrd5om7r27QBG2Y6oAzIxwzw6PwweN3t6x94k0uMLGDdfUO6vJFW6rEr-NFMp9w_h0GO/s200/aluminum+pistol+replica+with+suppressor+attached.JPG" title="homemade foundry sand casting" width="120" /></a></td></tr>
</tbody></table>
Anyway here is another useless item that I have created, It will serve as an excellent paper weight.<br />
<div>
I am thinking perhaps to place the pistol replica in a wooden box with a glass front and to printed on the glass "IN CASE OF A ZOMBIE ATTACK KEEP IT SILENT" ;-)....If and when I make the box I will add a photo to this post.</div>
FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-17473924739702595732013-01-04T08:18:00.000-08:002013-02-25T12:41:31.931-08:00Foundry Sand Casting Project For My Kids Room<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuoa2gR1XoH7iYb1auNp9GYS9HCivpepaR3XPzffQPn_1HkPwhq2fzr_2CLMTb5f_53Qhx0lp7VsngoPtkQdGOhbsvWoOwtJlcJiuN_Y4SRhLmCUiC5t-ZNokoboAvnmVx_mwLyGfjcG_h/s1600/recycling+aluminum+into+something+new.PNG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img alt="recycling scrap aluminum" border="0" height="171" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuoa2gR1XoH7iYb1auNp9GYS9HCivpepaR3XPzffQPn_1HkPwhq2fzr_2CLMTb5f_53Qhx0lp7VsngoPtkQdGOhbsvWoOwtJlcJiuN_Y4SRhLmCUiC5t-ZNokoboAvnmVx_mwLyGfjcG_h/s320/recycling+aluminum+into+something+new.PNG" title="homemade foundry casting" width="320" /></a></div>
This is my first post for 2013, in this post I will explain how I created decorative animal shapes casted from aluminum. I decided I wanted to make a big toy drawer to clear all the mess in my kids room, at first I thought of making just MDF shapes and paint them but then I thought it will be really cool if the animal shapes where from solid shiny aluminum. I collected some scrap metal and came across an old unused pressure cooker, so I decided to melt it in my homemade foundry and recycle it into something new. The first step was of course creating the casting patterns. I used 5mm MDF to create the elephants, dolphins and kangaroo pattern and green sand to create the sand mold impression.<br />
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<tr> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdDQlW2UgbsHW3LzY1LDVq1j7Q42tiKVDGJy7f_Xkb-xSgg8Y90VBIKldb23xXdp6Tk_91JdOnDQn2-H-mHa6HHhL5_7Htq2gsPfJSegQVOC9aX7_sI0dt_6D_n4juKPY_A7gWlDpOnk05/s1600/foundry+sand+casting+2.PNG" imageanchor="1"><img alt="sand casting process " border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdDQlW2UgbsHW3LzY1LDVq1j7Q42tiKVDGJy7f_Xkb-xSgg8Y90VBIKldb23xXdp6Tk_91JdOnDQn2-H-mHa6HHhL5_7Htq2gsPfJSegQVOC9aX7_sI0dt_6D_n4juKPY_A7gWlDpOnk05/s320/foundry+sand+casting+2.PNG" title="first stage of sand casting" width="150" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPP4-KvE6ogg-CElL7C7xi9Wib-1ngNyOqwzdj56XaJXB9Y9htgtYHnH5kyeGgf9tteqmFCjHitvmeGdgn7UPc2b4yXgNT9fgxx7l7RFLdarOwwxQThH1bNJjCsnAEltVHi20ZN9G_Xcys/s1600/foundry+sand+casting+I.PNG" imageanchor="1"><img alt="sand casting process" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPP4-KvE6ogg-CElL7C7xi9Wib-1ngNyOqwzdj56XaJXB9Y9htgtYHnH5kyeGgf9tteqmFCjHitvmeGdgn7UPc2b4yXgNT9fgxx7l7RFLdarOwwxQThH1bNJjCsnAEltVHi20ZN9G_Xcys/s320/foundry+sand+casting+I.PNG" title="second stage of sand casting" width="150" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgG9x4qcUCbXl3QghPAOpj_JI_7caK2bQf7Ixhcei0lhyphenhyphenVdly0KU_PfaEDvLD_DxhMUdPO28nRIchbvMf_dLX7FDkhRjqS0eOhEi2MNpq2TpbouXjCSAMMSCGM-dj5cKXXj7NtinYN2MwCY/s1600/foundry+flask+cope+part.PNG" imageanchor="1"><img alt="foundry flask cope part" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgG9x4qcUCbXl3QghPAOpj_JI_7caK2bQf7Ixhcei0lhyphenhyphenVdly0KU_PfaEDvLD_DxhMUdPO28nRIchbvMf_dLX7FDkhRjqS0eOhEi2MNpq2TpbouXjCSAMMSCGM-dj5cKXXj7NtinYN2MwCY/s320/foundry+flask+cope+part.PNG" title="sand casting flask cope" width="150" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifA3XBxfaqyc5z7nbRvlhCH3DzZAcQiIB48Gmx1JiYUumhd9vQfb_Z4Er8r9UIQUpMUJnT66iRMCFygsVrD-rnWjz_9qzeVa37rWISFtjSeHyQ9Tbwz5jfqLgbfjjAF91Gl5JYI__HFmbP/s1600/foundry+flask+drag+part.PNG" imageanchor="1"><img alt="foundry flask drag part" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifA3XBxfaqyc5z7nbRvlhCH3DzZAcQiIB48Gmx1JiYUumhd9vQfb_Z4Er8r9UIQUpMUJnT66iRMCFygsVrD-rnWjz_9qzeVa37rWISFtjSeHyQ9Tbwz5jfqLgbfjjAF91Gl5JYI__HFmbP/s320/foundry+flask+drag+part.PNG" title="sand casting flask drag" width="150" /></a></td></tr>
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I started first making the sand mold for the elephants and dolphin's. As you can see the flask was a bit small for the kangaroos pattern so I used another smaller wooden flask for them. I also used green sand in order to create the pattern impressions in the sand, the process was easy working with a flat pattern.<br />
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<tr> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhijGHVUwOlU26geOG3IItspNys5i9koKS_JGr0y9t4xm-6IgfknRNpxF42cCYhvUwj9UNv5INUgjLfSoOPPbggmyXWhnU6ygeN4-SGVAO_xJ7zhZWjNpUWIr_O5Mr4R0rpjdHM0IrG-S1c/s1600/kangaroo+pattern+impression+in+cope+part.PNG" imageanchor="1"><img alt="wooden foundry flask cope part" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhijGHVUwOlU26geOG3IItspNys5i9koKS_JGr0y9t4xm-6IgfknRNpxF42cCYhvUwj9UNv5INUgjLfSoOPPbggmyXWhnU6ygeN4-SGVAO_xJ7zhZWjNpUWIr_O5Mr4R0rpjdHM0IrG-S1c/s320/kangaroo+pattern+impression+in+cope+part.PNG" title="casting aluminum kangaroo flask cope part" width="150" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpb8Aip_bi5DWf2ZOltKZ86SXtxTLZZgZ9Hz_IYeyl-vdPjHkaK-QNzDeIF9p3Cv_4VkENdJMvEyAb4ZoQs8NykGjW6F8WG804THhcwx1xVOw0rFhGTTY-qgcjWJZzXogoqOM7qoQHky_N/s1600/kangaroo+pattern+in+flask.PNG" imageanchor="1"><img alt="wooden foundry flask with pattern" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpb8Aip_bi5DWf2ZOltKZ86SXtxTLZZgZ9Hz_IYeyl-vdPjHkaK-QNzDeIF9p3Cv_4VkENdJMvEyAb4ZoQs8NykGjW6F8WG804THhcwx1xVOw0rFhGTTY-qgcjWJZzXogoqOM7qoQHky_N/s320/kangaroo+pattern+in+flask.PNG" title="casting aluminum kangaroo drag part" width="150" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxLz3BAoGX22rrL45gU_uIDu6l15QRDBhAXWFiePTfoNfpwFMXlfUXkzhcbp8Vzp1_NRJW9krl8IqCBLdsCf4sLyrqFsEZLzKO7lMrOVfUkQXVcXr-hQSaZNs3eIulNrhaULdhin7_uCjN/s1600/kangaroo+pattern+in+flask+covered+with+parting+poweder.PNG" imageanchor="1"><img alt="foundry flask covered with parting powder" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxLz3BAoGX22rrL45gU_uIDu6l15QRDBhAXWFiePTfoNfpwFMXlfUXkzhcbp8Vzp1_NRJW9krl8IqCBLdsCf4sLyrqFsEZLzKO7lMrOVfUkQXVcXr-hQSaZNs3eIulNrhaULdhin7_uCjN/s320/kangaroo+pattern+in+flask+covered+with+parting+poweder.PNG" title="foundry sand casting with parting powder" width="150" /></a></td> <td></td> </tr>
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After casting the aluminum animal shapes I cleaned all the extra aluminum with a metal file then sanded it with an electric sander. Once the cleaning part was done it was time to drill the brass screw holes and to start the polishing process. I think this process is the most time consuming part and it takes a lot of patience to get a<br />
good result ;-)<br />
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<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitGawluWLOJWKyCH567q51GTm-OrUGczUD7uQLqHNNw-S33K7XUPdnKQ4G61lZp542eiBjs5epI3Wg8NpQkIYkzNHb1X8l44p_nx84zORRE9VR2rFqFDysDOXbGI_aiIX5Xaph3Z5wRQPR/s1600/aluminum+casting+after+opening+the+flask.PNG" imageanchor="1"><img alt="after opening the foundry flask" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitGawluWLOJWKyCH567q51GTm-OrUGczUD7uQLqHNNw-S33K7XUPdnKQ4G61lZp542eiBjs5epI3Wg8NpQkIYkzNHb1X8l44p_nx84zORRE9VR2rFqFDysDOXbGI_aiIX5Xaph3Z5wRQPR/s200/aluminum+casting+after+opening+the+flask.PNG" title="sand casting of elephant and dolphin" width="125" /></a></td><td><a 0="0" height="95" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwBjJiG_IGjXskq98Yt3BR3oonpySTBamYisWkt5-gBgogUMN-k15q4qM3r4CnqBlxAaOVMyi-BtsfxAZ992aI1srB76_LjaWUmBJFdmSkYHEpvxVlw2z8dMH54_Xex8SYiEsFPSmoB5xu/s1600/first+aluminum+polish.PNG" imageanchor="><img border=" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwBjJiG_IGjXskq98Yt3BR3oonpySTBamYisWkt5-gBgogUMN-k15q4qM3r4CnqBlxAaOVMyi-BtsfxAZ992aI1srB76_LjaWUmBJFdmSkYHEpvxVlw2z8dMH54_Xex8SYiEsFPSmoB5xu/s200/first+aluminum+polish.PNG" width="125"></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjz0LeMEFy5wK6v5IXC278W5NqbR5oYm7Bf7hE50DJ1xH33nblGkwBfWODKLxHlV25B9_Kkog3Lu9XGXqNMZIYrKFdN5Fd006ezH3IVdbhfxSVSxf9N_d97XiHEqGuuwW4Z5RNcV9x-hec/s1600/cleaned+aluiminum+casting.PNG" imageanchor="1"><img alt="first stage of cleaning the aluminum casting" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjz0LeMEFy5wK6v5IXC278W5NqbR5oYm7Bf7hE50DJ1xH33nblGkwBfWODKLxHlV25B9_Kkog3Lu9XGXqNMZIYrKFdN5Fd006ezH3IVdbhfxSVSxf9N_d97XiHEqGuuwW4Z5RNcV9x-hec/s200/cleaned+aluiminum+casting.PNG" title="first stage after cleaning the aluminum casting" width="125" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgCxe0rPfp4AUzqOv3jdiFMTm3v1V8u1VKK8pklLnjeOuvNynN-slsUT8ZVcDQPyBPaWkdSLKXTAli8jrZzKBxg-4Iwi1ACCWxJmJxrunRDFMopsu29AWoH0aLYKwN1i-KQArjraKLty5U/s1600/aluminum+elephants+kangaroos+and+dolphins+casting.PNG" imageanchor="1"><img alt="all aluminum casting together " border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgCxe0rPfp4AUzqOv3jdiFMTm3v1V8u1VKK8pklLnjeOuvNynN-slsUT8ZVcDQPyBPaWkdSLKXTAli8jrZzKBxg-4Iwi1ACCWxJmJxrunRDFMopsu29AWoH0aLYKwN1i-KQArjraKLty5U/s200/aluminum+elephants+kangaroos+and+dolphins+casting.PNG" title="all aluminum castings and sprue still connected" width="125" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQh2FgsEBen4hbZF6VXtOZtidqhH-AcKo6yixQLBsTeuk6OlQtSwqWcX7oE3iY-C2KytzcRg2So5MP0un3CH8VZnMCe2HW7UNn3o64DmdGzeO5uNW7k1X0He0GxAT4eco06euYz1WAL18z/s1600/aluminum+kangaroo+casting.PNG" imageanchor="1"><img alt="kangaroo aluminum casting" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQh2FgsEBen4hbZF6VXtOZtidqhH-AcKo6yixQLBsTeuk6OlQtSwqWcX7oE3iY-C2KytzcRg2So5MP0un3CH8VZnMCe2HW7UNn3o64DmdGzeO5uNW7k1X0He0GxAT4eco06euYz1WAL18z/s200/aluminum+kangaroo+casting.PNG" title="aluminum casting of kangaroo with sprue" width="125" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwBjJiG_IGjXskq98Yt3BR3oonpySTBamYisWkt5-gBgogUMN-k15q4qM3r4CnqBlxAaOVMyi-BtsfxAZ992aI1srB76_LjaWUmBJFdmSkYHEpvxVlw2z8dMH54_Xex8SYiEsFPSmoB5xu/s1600/first+aluminum+polish.PNG" imageanchor="1"><img alt="using metal file to clean aluminum casting" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwBjJiG_IGjXskq98Yt3BR3oonpySTBamYisWkt5-gBgogUMN-k15q4qM3r4CnqBlxAaOVMyi-BtsfxAZ992aI1srB76_LjaWUmBJFdmSkYHEpvxVlw2z8dMH54_Xex8SYiEsFPSmoB5xu/s320/first+aluminum+polish.PNG" title="cleaning aluminum casting with metal file" width="125" /></a></td></tr>
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I was really happy with the final results and it looks very nice hanging on the new toy drawer. I'm now thinking on how to create a larger pattern of some sort of shape but that's for a future post when i"ll have a new idea ;-)<br />
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<tr> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvNy7k4QQMoZlBJuz6A418CIFpK6kAMTB26SBPxKK8r6LA8VUpVuivH05XC1voIS_8ujTGdhHV6zsU3SX-0xoE_vIqR0MJtmktVL5RbAI3OD8yURg5V8P_SkjgxO1m-8JO7dglDRFffduR/s1600/building+the+under+bed+drawer.PNG" imageanchor="1"><img alt="new kids toy drawer" border="0" height="120" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvNy7k4QQMoZlBJuz6A418CIFpK6kAMTB26SBPxKK8r6LA8VUpVuivH05XC1voIS_8ujTGdhHV6zsU3SX-0xoE_vIqR0MJtmktVL5RbAI3OD8yURg5V8P_SkjgxO1m-8JO7dglDRFffduR/s320/building+the+under+bed+drawer.PNG" title="building MDF under bed toy drawer" width="180" /></a></td> <td></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2C5G04MK-eicPusBbg_UxJuIRVESjufTw-ylzvDHSlf26v74RtR0VbYwpNXOv9dQhfdmICMh5nsm8pDLC0s3_iXWyuVdxxPx4R4Lfo31nneGmtCdtD8Ttae5FcAhKQ1CaJbViuA75yKdF/s1600/aluminun+casting+attached+to+bed+2.PNG" imageanchor="1"><img alt="aluminum shapes attached to toy drawer" border="0" height="120" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2C5G04MK-eicPusBbg_UxJuIRVESjufTw-ylzvDHSlf26v74RtR0VbYwpNXOv9dQhfdmICMh5nsm8pDLC0s3_iXWyuVdxxPx4R4Lfo31nneGmtCdtD8Ttae5FcAhKQ1CaJbViuA75yKdF/s320/aluminun+casting+attached+to+bed+2.PNG" title="aluminum casting shapes attached to toy drawer" width="180" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTjn4CKsWl_dsZjo5GMnYkLpwV43BJ3RkGoQBwQ6gtJ4-aaeMLS2VuVqnCJzhpA1727MFt1cxjCGcCgpfWImAi1n6i0C6kB5pHrzxktlrVM7ByeOnVHV4iVJTaFQIpJPNG_85mP6sIlOwr/s1600/sand+casting+aluminum+elephant%252C+dolphin%252C+kangaroo.PNG" imageanchor="1" style="margin-left: 0em; margin-right: 0em; text-align: center;"><img alt="aluminum casting" border="0" height="140" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTjn4CKsWl_dsZjo5GMnYkLpwV43BJ3RkGoQBwQ6gtJ4-aaeMLS2VuVqnCJzhpA1727MFt1cxjCGcCgpfWImAi1n6i0C6kB5pHrzxktlrVM7ByeOnVHV4iVJTaFQIpJPNG_85mP6sIlOwr/s200/sand+casting+aluminum+elephant%252C+dolphin%252C+kangaroo.PNG" title="homemade foundry casting" width="210" /></a></td></tr>
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</div>
FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-61969096067447479552013-01-04T08:15:00.000-08:002013-02-16T12:54:58.852-08:00Backyard Metal Casting Setup Information<span style="font-family: Arial, Helvetica, sans-serif;">In this post I am going to try and cover for those who are interested in the setup of a home made/backyard foundry. This is all based on my experience with aluminum metal casting. I tried different methods learning mostly by reading about metal casting and practical trial and error, whatever worked the best for me ;-)</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;">I have to state that this post as all my other posts is based on my experience and is not a guide on "how to".</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;">If anyone decides to use my method he will to do it on his on risk, I advice you read my site safety deceleration.</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;">So lets get started: the <b><u>most important </u></b>part of running a homemade foundry is having all the necessary P.P.E. Always work with full body protective gear head to toe when handling molten metal never cut corners on this part. The main components for a homemade foundry are:</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;"><br />
</span><br />
<ul>
<li><span style="font-family: Arial, Helvetica, sans-serif;">All <u><b><span style="color: red;">P.P.E </span></b></u>designated for foundry to protect the metal caster from molten metal injuries.</span></li>
<li><span style="font-family: Arial, Helvetica, sans-serif;">Well insulated <b><u><span style="color: red;">foundry</span> </u></b>for example using an old gas cylinder, metal bin, flower pot etc'. When I say insulated I mean good refractory to keep all the heat in the furnace. </span></li>
<li><span style="font-family: Arial, Helvetica, sans-serif;">Foundry <b><u><span style="color: red;">energy source</span></u> </b>to heat the solid aluminum bringing it to 660°C (melting point). This could be achieved with charcoals + air blower, Gas burner, waste oil burner or an electric furnace. Every energy source has its advantages and disadvantages.</span></li>
<li><span style="font-family: Arial, Helvetica, sans-serif;"><span style="color: red;"><b><u>Crucible</u></b> </span>is the container that holds the solid aluminum parts until it turns into molten metal. The foundry crucible has to be solid enough to withstand the high temperature without breaking. A bad crucible could result in loosing all the molten metal at the bottom of the furnace. There are different types of commercial crucibles such as clay graphite crucibles, silicon carbide crucibles, ceramic crucibles and more. I will focus on a homemade metal crucible.</span></li>
<li><span style="font-family: Arial, Helvetica, sans-serif;"><span style="color: red;"><b><u>Foundry tools</u></b> </span>such as crucible lifting tool / tongs, crucible dross skimming spoon, water pump pliers.</span></li>
<li><span style="font-family: Arial, Helvetica, sans-serif;"><b><u><span style="color: red;">Ingot tray</span></u></b> some sort of container that will hold the left over aluminum from every casting. It is possible to use a metal muffin tray to get nice and neat ingots or to weld L bars for larger ingots (easy solution for stacking).</span></li>
<li><span style="font-family: Arial, Helvetica, sans-serif;"><span style="color: red;"><b><u>Molding sand</u></b> </span>either <u>green sand</u> or<u> oil bonded sand</u>. Both are good for casting aluminum parts.</span></li>
<li><span style="font-family: Arial, Helvetica, sans-serif;"><span style="color: red;"><b><u>Foundry flask</u></b> </span>for sand casting, either from timber or metal is good as long as the cope and drag parts align.</span></li>
<li><span style="font-family: Arial, Helvetica, sans-serif;"><b><u><span style="color: red;">Aluminum source</span></u></b> there are many objects around us made of aluminum that can easily be melted and recycled into a new object. A good source of aluminum could be found in car engine parts such as an engine block, bell housing etc'.</span></li>
</ul>
<span style="font-family: Arial, Helvetica, sans-serif;">First I will start explaining about a homemade crucible. I have experimented with different types of crucible mostly made from metal. I started using food cans and a kitchen pot, I would <b style="text-decoration: underline;"><span style="color: red;">not</span></b><u> recommend </u>anyone to use cans or pots as crucible the metal is very thin and it will break very quickly under the high temperature of the foundry (see image below). The molten metal can end at the bottom of the furnace or worst case scenario on the metal casters feet. So a big no no for food cans as crucible. After using a metal pipe as a crucible that was too narrow was no use at all. Then I used a square crucible the metal was a bit thicker and lasted for about 10-20 casting sessions but eventually gave in and the molten metal ended at the bottom of my foundry. See image of aluminum blob. It took me a lot of time to get the solidified aluminum blob out from the bottom of the furnace, I have remelted it back into ingots.</span><br />
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<tr> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVKBRrhdtdo591jk7Qzm5Eon8ypZn5xT_SNxDoZvCF6Uj_bEdocHItfPqPvBXdtRlIKYeBtFraBZqvzHrmsyqrTuMFB6zV4Sox3zOaCnLW_jIXsQyqmnd40S_1eInaCcQ61aypqIRhmicQ/s640/foundry%2520crucible.JPG" imageanchor="1"><img alt="foundry metal crucible" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVKBRrhdtdo591jk7Qzm5Eon8ypZn5xT_SNxDoZvCF6Uj_bEdocHItfPqPvBXdtRlIKYeBtFraBZqvzHrmsyqrTuMFB6zV4Sox3zOaCnLW_jIXsQyqmnd40S_1eInaCcQ61aypqIRhmicQ/s640/foundry%2520crucible.JPG" title="Different foundry crucible sizes" width="150" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_av2tTAhJ24ueK3-Px4NgcVSoVwgC62n6b-PT_3AsB2Mtn_tfjz0LrSiW0OhJzlWf4y8g6tmfqYat2rrogabai_yOwo4GHTVeB8nZVhf80ruvBzP90WfFx4jnQhabi4thffR7UiTlTty3/s800/melted%2520aluminum%2520blob.JPG" imageanchor="1"><img alt="Aluminum blob" border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_av2tTAhJ24ueK3-Px4NgcVSoVwgC62n6b-PT_3AsB2Mtn_tfjz0LrSiW0OhJzlWf4y8g6tmfqYat2rrogabai_yOwo4GHTVeB8nZVhf80ruvBzP90WfFx4jnQhabi4thffR7UiTlTty3/s800/melted%2520aluminum%2520blob.JPG" title="Aluminum blob botttom of foundry" width="150" /></a></td> <td></td> </tr>
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<span style="font-family: Arial, Helvetica, sans-serif;">At this stage I decided to make a proper metal crucible that will last me longer. Two things where important for me, first to make it as safe as possible and secondly to get max volume of molten aluminum out of it as my foundry is relatively small.</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;">I used old scrap metal from a broken scooter to make all the crucible lifting tools.</span><br />
<span style="font-family: Arial, Helvetica, sans-serif;">The only part I purchased from a metal fabricator factory was a metal pipe size: 140mm-Diameter and 8mm-thickness. I asked the guy in the factory to cut two sizes one: 200mm (H) the other 110mm (H). Its more convenient to use smaller crucibles for small casting projects. I also bought a metal base plate 5mm -thick for the crucible. I cut the metal plate with an angle grinder into a octagon shape that way it fit nicely into the foundry cavity. I also threaded two bolts into the sides of the crucible to be used with the crucible lifting tool.</span><br />
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<tr> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPGC2NcHKxBtuHbvrxvhcf6cGGr8a-JVQJCd4PY7eAmUZjkx5hxQn13bqm5TGKJMJVxpSDT9No6ax8Gc9TD9b9Kav4UPgLh6OjZM4cOzygd1g83biSxZ1QF_DnWS13ZCrEHOfgiE0l5ZmU/s800/metal%2520foundry%2520crucible.JPG" imageanchor="1"><img alt="two metal crucibles" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPGC2NcHKxBtuHbvrxvhcf6cGGr8a-JVQJCd4PY7eAmUZjkx5hxQn13bqm5TGKJMJVxpSDT9No6ax8Gc9TD9b9Kav4UPgLh6OjZM4cOzygd1g83biSxZ1QF_DnWS13ZCrEHOfgiE0l5ZmU/s800/metal%2520foundry%2520crucible.JPG" title="Metal crucible before welding" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEig7DbNFeYA_wxgFO_dwjSSJnhqwvXYVW3f-5mBKwy5zI26jMBdSd1WeVfagjrO1kHLl5E_iNuTjrRkqIF0ZKxRARbw1GaHPXr4O6bWJloJwfJIfROsue83donnvvR43-4yMFUlfwnsogBo/s800/prepering%2520foundry%2520crucible.JPG" imageanchor="1"><img alt="Metal crucible base" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEig7DbNFeYA_wxgFO_dwjSSJnhqwvXYVW3f-5mBKwy5zI26jMBdSd1WeVfagjrO1kHLl5E_iNuTjrRkqIF0ZKxRARbw1GaHPXr4O6bWJloJwfJIfROsue83donnvvR43-4yMFUlfwnsogBo/s800/prepering%2520foundry%2520crucible.JPG" title="Cutting crucible base" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCBBPZ3xe4UnJ4l48KtTVfC_DIKy7tFi3E3FColFKEtZcag_GERAHJRbrYhF3IfYOuZDUrgUEMc4Y7hjTSn9NidOg9xkiwKR_dODMz4g5TBBOC0XU9bF_1P2LLrt-uTFWVjubtAi7WNXrh/s800/DSCN6658%2520%2528Small%2529.jpg" imageanchor="1"><img alt="About to melt my old aluminum sand rammer" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCBBPZ3xe4UnJ4l48KtTVfC_DIKy7tFi3E3FColFKEtZcag_GERAHJRbrYhF3IfYOuZDUrgUEMc4Y7hjTSn9NidOg9xkiwKR_dODMz4g5TBBOC0XU9bF_1P2LLrt-uTFWVjubtAi7WNXrh/s800/DSCN6658%2520%2528Small%2529.jpg" title="metal crucible ready for use" width="120" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh75O8MN_JB0-TzTI6-nveVJ0bTwJJo7fntgCbgeu_VxA3ix9swSed6lJZtcKA7RJg-rGw_PT30fHaI0BZH8NGOMvlbu3bvBcV9_u2NHY7aGZOUXqRAMYqY5OZXZCF-cuGFM66F8wo04Be1/s800/welding%2520foundry%2520crucible.JPG" imageanchor="1"><img alt="After welding crucible base" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh75O8MN_JB0-TzTI6-nveVJ0bTwJJo7fntgCbgeu_VxA3ix9swSed6lJZtcKA7RJg-rGw_PT30fHaI0BZH8NGOMvlbu3bvBcV9_u2NHY7aGZOUXqRAMYqY5OZXZCF-cuGFM66F8wo04Be1/s800/welding%2520foundry%2520crucible.JPG" title="Welded metal crucible" width="120" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQ0qMk5p9fa31_ptf0E805iCbBhZGcKgiQ6Lv5OMFWFPIh2qkEqMNlst76fulUi-QAE2yMHYNEuGeToidoToZWvT84lPuEgH8kkB21NQ5IbntglY0va0XqhyYtzJnwdM-wsTE6diV67Wdc/s800/small%2520foundry%2520crucible.jpg" imageanchor="1"><img alt="Crucible in fire with molten aluminum" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQ0qMk5p9fa31_ptf0E805iCbBhZGcKgiQ6Lv5OMFWFPIh2qkEqMNlst76fulUi-QAE2yMHYNEuGeToidoToZWvT84lPuEgH8kkB21NQ5IbntglY0va0XqhyYtzJnwdM-wsTE6diV67Wdc/s800/small%2520foundry%2520crucible.jpg" title="crucible first use" width="120" /></a></td></tr>
</tbody></table>
<span style="font-family: Arial, Helvetica, sans-serif;">Next stage was to make the lifting tool, I have used scrap metal for this part. The lifting tool is made from two parts the actual lifting tool and a tilting tool.</span><br />
<div>
<span style="font-family: Arial, Helvetica, sans-serif;">The lifting tool is constructed from an old scooter and square iron tube and the tilting handle I made by welding a re-bar into an L-shape.</span></div>
<table><tbody>
<tr> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLw1HlHYq2Ixmu2bBXkXcfBY9A-QGOZzXkCbCWH43r4kVZjhCXU0OwZafcCn-faJ6hHhbdne2bVgY-KDT9810z-54HTdrqfkGXPNzdbFFrx7v0KvD06BI2vmt3CeXdOSre3IVE4B9kVBx1/s800/foundry%2520crucible%2520lifting%2520tool%25201.JPG" imageanchor="1"><img alt="used scooter scrap metal" border="0" height="110" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLw1HlHYq2Ixmu2bBXkXcfBY9A-QGOZzXkCbCWH43r4kVZjhCXU0OwZafcCn-faJ6hHhbdne2bVgY-KDT9810z-54HTdrqfkGXPNzdbFFrx7v0KvD06BI2vmt3CeXdOSre3IVE4B9kVBx1/s800/foundry%2520crucible%2520lifting%2520tool%25201.JPG" title="old scooter " width="100" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1shmQkroUaKxVcrz7WPfFA4WCAzCEmbYBsybXmQxzxn77Q8QHiC4GnftxKQklCnqQ_KLUvZn-nTpXuI6JqIVoGmSU0Lqof-4mUvM-B5mpgssIOhXTr9WvWmUg6A1OGi9LcvbKMmpkjfIv/s800/foundry%2520crucible%2520liofting%2520tool%25202.jpg" imageanchor="1"><img alt="after cutting metal to correct size" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1shmQkroUaKxVcrz7WPfFA4WCAzCEmbYBsybXmQxzxn77Q8QHiC4GnftxKQklCnqQ_KLUvZn-nTpXuI6JqIVoGmSU0Lqof-4mUvM-B5mpgssIOhXTr9WvWmUg6A1OGi9LcvbKMmpkjfIv/s800/foundry%2520crucible%2520liofting%2520tool%25202.jpg" title="scooter part" width="100" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicHDP3w0iWAgf4jLg7NVigs35j7l0XhdNLeZ-tFwDbVMxdkquP_WYgnU3GWCcdLr_NgUwz3_kgtFPShkBepd02V4CdRaIH1zCc6gBQ3g50pzRbA8jWjAzo8jn8S-dgS9MhTkOiTg2QApQU/s800/foundry%2520crucible%2520lifting%2520tool%25204.jpg" imageanchor="1"><img alt="Drilling crucible lifting tool part" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicHDP3w0iWAgf4jLg7NVigs35j7l0XhdNLeZ-tFwDbVMxdkquP_WYgnU3GWCcdLr_NgUwz3_kgtFPShkBepd02V4CdRaIH1zCc6gBQ3g50pzRbA8jWjAzo8jn8S-dgS9MhTkOiTg2QApQU/s800/foundry%2520crucible%2520lifting%2520tool%25204.jpg" title="foundry part in vice" width="100" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3tZhER2X4MfoHvmyXLti19uq4bSpt7zuIrPrJ-0pSOxiRKEoYswrs4-x4hDcDdxEJh8Gpk4F9c_avmdBGuChIBsNYIuccc1sf3eBG93kAdmjGYEBCCiIikjrNzGG1DtXSbqI9vP-xyZlO/s800/foundry%2520crucible%2520lifting%2520tool%25203.jpg" imageanchor="1"><img alt="cutting the crucible lifting parts" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3tZhER2X4MfoHvmyXLti19uq4bSpt7zuIrPrJ-0pSOxiRKEoYswrs4-x4hDcDdxEJh8Gpk4F9c_avmdBGuChIBsNYIuccc1sf3eBG93kAdmjGYEBCCiIikjrNzGG1DtXSbqI9vP-xyZlO/s800/foundry%2520crucible%2520lifting%2520tool%25203.jpg" title="crucible lifting parts" width="100" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwFq-iL3evayHm7mfjQLOyOuUe4iFassMJUVv49KmpjpLCrt_KpEpGocheweNwibRhB27mFheYZKPufi2kBJWt3XnQEUU-IqaYV7dLMoGmB8mdUvAsrfu3GBA5qCjg3Tyarz9lpX3kuDeD/s800/foundry%2520crucible%2520lifting%2520tool%25205.jpg" imageanchor="1"><img alt="fabricating the crucible lifting parts" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwFq-iL3evayHm7mfjQLOyOuUe4iFassMJUVv49KmpjpLCrt_KpEpGocheweNwibRhB27mFheYZKPufi2kBJWt3XnQEUU-IqaYV7dLMoGmB8mdUvAsrfu3GBA5qCjg3Tyarz9lpX3kuDeD/s800/foundry%2520crucible%2520lifting%2520tool%25205.jpg" title="Crucible lifting parts" width="100" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdMqIbd3L5T92FMGawoFcb4GwTSG_yICCxTcJe8Dbl03JgOKkiCAQH2MgYKNkRvV2QrKjVWU6CkIH7sQYSuR40XUeQEytOcxbsxHu5bE7ivhkmgjZ9fBwQ23piKBIPSD4hUdTgz60TuVmT/s800/foundry%2520crucible%2520lifting%2520tool%25206.jpg" imageanchor="1"><img alt="attaching bolts to crucible lifting tool" border="0" height="80" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdMqIbd3L5T92FMGawoFcb4GwTSG_yICCxTcJe8Dbl03JgOKkiCAQH2MgYKNkRvV2QrKjVWU6CkIH7sQYSuR40XUeQEytOcxbsxHu5bE7ivhkmgjZ9fBwQ23piKBIPSD4hUdTgz60TuVmT/s800/foundry%2520crucible%2520lifting%2520tool%25206.jpg" title="crucible lifting tool finished" width="100" /></a></td> </tr>
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<div>
<span style="font-family: Arial, Helvetica, sans-serif;">After making the lifting tools its important to check that they work well ,for example lifting the crucible in and out of the foundry checking that nothing gets in the way. Its also very important to make sure that while lifting the crucible and tilting the crucible that it won't fall out of the lifting tool notches. The last tool and the most easiest one to make is the foundry skimming tool. Its always good practice to make a long handle for the skimming spoon. I made my skimming spoon from a metal rod and I welded to it a large kitchen spoon.</span></div>
<table><tbody>
<tr> <td><span style="font-family: Arial, Helvetica, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimTqlnPzgzJ2_eWIDvjqoQ-91ux3cMgY4_TZS8C3QmoEDgJvcgue9OQjlxHrzqZpmnwy3wa-t0OWRhhva8qHEvMXkjfc2XOHOfgqcUiw7IiL54aqqs3dS-xioZyDODqXhvtreyRnJ_maBb/s800/aluminum%2520foundry%2520lifting%2520tool%252010.jpg" target="_blank"><img alt="after finishing the foundry tools" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimTqlnPzgzJ2_eWIDvjqoQ-91ux3cMgY4_TZS8C3QmoEDgJvcgue9OQjlxHrzqZpmnwy3wa-t0OWRhhva8qHEvMXkjfc2XOHOfgqcUiw7IiL54aqqs3dS-xioZyDODqXhvtreyRnJ_maBb/s1600/aluminum+foundry+lifting+tool+10.jpg" target="_blank" title="foundry tools finished" width="105" /></a></span></td> <td><span style="font-family: Arial, Helvetica, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUnFOyqBIYZUFSamLx4Y68wJ-6iNZnNBicIIpleFDlfp83uSJ-sgnK7pVNr_WZm49_ehWfJ3_ZT5cWHlfgtmBtDUQDUdXxSPKdK5_wsx8iB75SBXKGnljUeKnv7vdYgAYkihN-yEFc79QN/s800/aluminum%2520foundry%2520lifting%2520tool%25207.jpg" target="_blank"><img alt="dry ftest of crucible and lifting tool" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUnFOyqBIYZUFSamLx4Y68wJ-6iNZnNBicIIpleFDlfp83uSJ-sgnK7pVNr_WZm49_ehWfJ3_ZT5cWHlfgtmBtDUQDUdXxSPKdK5_wsx8iB75SBXKGnljUeKnv7vdYgAYkihN-yEFc79QN/s1600/aluminum+foundry+lifting+tool+7.jpg" target="_blank" title="crucible tool" width="105" /></a></span></td> <td><span style="font-family: Arial, Helvetica, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVaKRYMLQ0MBcvHkFvq0AFN6H9SSEaUGUgZ0Bg0BGRC9Jo2W0AU25c2WJaUt5vkWGS37mZHcoFfBrBPpZe5r5LPGQh6Fv2U-nakvZTfIbjMUGRjCs49Xv8BxeOoZJ_bNKOwcd_kZQjKVOS/s800/aluminum%2520foundry%2520lifting%2520tool%25208.jpg" target="_blank"><img alt="foundry tools" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVaKRYMLQ0MBcvHkFvq0AFN6H9SSEaUGUgZ0Bg0BGRC9Jo2W0AU25c2WJaUt5vkWGS37mZHcoFfBrBPpZe5r5LPGQh6Fv2U-nakvZTfIbjMUGRjCs49Xv8BxeOoZJ_bNKOwcd_kZQjKVOS/s1600/aluminum+foundry+lifting+tool+8.jpg" target="_blank" title="foundry tools ready" width="105" /></a></span></td> <td><span style="font-family: Arial, Helvetica, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvbYCpl52Z0BESNSQi2Kp5tiDiJY31RrFkGvzPVDF2c_aOarMCq75o3avtQdvVFXGzzyPUUSQB0C6TveCWr8j6f3vEayQjjqOETvORFsiJ41I7fzs1Y-RFT2YYszcbMZzAfEOcquWQn6RU/s800/aluminum%2520foundry%2520lifting%2520tool%25209.jpg" target="_blank"><img alt="tilting crucible dry test" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvbYCpl52Z0BESNSQi2Kp5tiDiJY31RrFkGvzPVDF2c_aOarMCq75o3avtQdvVFXGzzyPUUSQB0C6TveCWr8j6f3vEayQjjqOETvORFsiJ41I7fzs1Y-RFT2YYszcbMZzAfEOcquWQn6RU/s1600/aluminum+foundry+lifting+tool+9.jpg" target="_blank" title="using foundry tools" width="105" /></a></span></td> <td><span style="font-family: Arial, Helvetica, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQwH8fLuoGXYDxEBK9RgQQnj_b4olTt807Af0tLFJn2fOi2fVgnLhBk6aXD4Owsx-mDRQPdRt388_wzt9F1hm0iQ8l_cUWO2YIXVnNR_J9gxQsOUcUSwoaWOZOkHc3aqcx0q-9GpkyEH3s/s800/foundry%2520crucible%2520%2520top.JPG" target="_blank"><img alt="bolts in cruciblee will be used to lift it" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQwH8fLuoGXYDxEBK9RgQQnj_b4olTt807Af0tLFJn2fOi2fVgnLhBk6aXD4Owsx-mDRQPdRt388_wzt9F1hm0iQ8l_cUWO2YIXVnNR_J9gxQsOUcUSwoaWOZOkHc3aqcx0q-9GpkyEH3s/s1600/foundry+crucible++top.JPG" target="_blank" title="threading bolt to crucible" width="105" /></a></span></td> <td><span style="font-family: Arial, Helvetica, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0kn1SVmKHB5YxxzDLGiKKeEXt49MFzE0FPFlT8OqXIHDm9VJeIx-liRSR0eJfMSWaRkEh1kZH-JdKVEILZ_nfc-LEmdXGKLYqa29XfUroN5hNcWxuUbDuIX3Kdw2z9oMW8BTPxf_dWUe2/s800/foundry%2520crucible%2520skimming%2520tool.JPG" target="_blank"><img alt="molten aluminum skimming spoon" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0kn1SVmKHB5YxxzDLGiKKeEXt49MFzE0FPFlT8OqXIHDm9VJeIx-liRSR0eJfMSWaRkEh1kZH-JdKVEILZ_nfc-LEmdXGKLYqa29XfUroN5hNcWxuUbDuIX3Kdw2z9oMW8BTPxf_dWUe2/s1600/foundry+crucible+skimming+tool.JPG" target="_blank" title="foundry skimming tool" width="105" /></a></span></td> </tr>
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<div>
<span style="font-family: Arial, Helvetica, sans-serif;">This metal crucible is excellent for backyard metal casting, I have used it many times and it works perfect in combination with the crucible tools. The next thing I needed is a good and functional ingot tray. Since I am using bigger crucible I am using more aluminum and the muffin tray that I used before is a bit small at this stage. Ingot tray size can vary depended on the size of the foundry and the volume of the castings. The new Ingot tray I made from welded L-bars. The triangular aluminum ingots make it easy to stack pile them. <span style="color: #cc0000;"><b>It is very important to preheat the ingot tray during every casting session just before pouring the molten metal into it. </b><b>I usually place the ingot tray on top of the hot foundry for a few minutes before pouring the molten metal into it.</b></span></span></div>
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<tr> <td><span style="font-family: Arial, Helvetica, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXDp1zDdeWrNbOwYL6DB74IN2a-P8sdNIPL47uxiVUBJ0dlnM03Gnt2VBFbUpNH0aey2u8urkA9CA_1_jimyYIbUPY2gJxRej6PD_OzfPeGN0REMQzM-PdaRjPetIg9aLCYePhM0W6FIEs/s800/aluminum%2520ingots%2520in%2520crucible.JPG" target="_blank"><img alt="checking crucible and ingot size" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXDp1zDdeWrNbOwYL6DB74IN2a-P8sdNIPL47uxiVUBJ0dlnM03Gnt2VBFbUpNH0aey2u8urkA9CA_1_jimyYIbUPY2gJxRej6PD_OzfPeGN0REMQzM-PdaRjPetIg9aLCYePhM0W6FIEs/s1600/aluminum+ingots+in+crucible.JPG" target="_blank" title="testing crucible" width="90" /></a></span></td> <td><span style="font-family: Arial, Helvetica, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9CpQmoZtxZtJ1ILn5l_jBZOSoNQIpfJjumshPaLoCl1BdbOWY46aK0D1GKomlL6pbGqRK0Igu0jaFZfwxIkHsl8rXB8NoS5ydBeEgkidW9s3qyUxEPFgxct4O99nok4SSEvQlIcOujDr8/s800/aluminum%2520ingots%2520size.JPG" target="_blank"><img alt="different aluminum ingots sizes" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9CpQmoZtxZtJ1ILn5l_jBZOSoNQIpfJjumshPaLoCl1BdbOWY46aK0D1GKomlL6pbGqRK0Igu0jaFZfwxIkHsl8rXB8NoS5ydBeEgkidW9s3qyUxEPFgxct4O99nok4SSEvQlIcOujDr8/s1600/aluminum+ingots+size.JPG" target="_blank" title="aluminum ingots" width="90" /></a></span></td> <td><span style="font-family: Arial, Helvetica, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFCTVYBnL4rmjcTYKTFJiyOYgxKpAkJtn2rBA9VPQAZ1l3G80YCaI1J_4sdNUXm5i1TR7cSeo8NOPLUufs1hzSUatLUPeIRxr-JUllIBAkV614vVtbwVVuFDWlRAMoBxJ556VI0LG5WNGT/s800/aluminum%2520ingots%2520tray.JPG" target="_blank"><img alt="muffin tray for aluminum ingots" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFCTVYBnL4rmjcTYKTFJiyOYgxKpAkJtn2rBA9VPQAZ1l3G80YCaI1J_4sdNUXm5i1TR7cSeo8NOPLUufs1hzSUatLUPeIRxr-JUllIBAkV614vVtbwVVuFDWlRAMoBxJ556VI0LG5WNGT/s1600/aluminum+ingots+tray.JPG" target="_blank" title="foundry ingot tray" width="90" /></a></span></td> <td><span style="font-family: Arial, Helvetica, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMqvZXyknG0npTLapuf0jiohxPXpTPcZc8mP4_gTmRGUR8HDLdLl3nsaK5PtCPUDOWBBIs2Dqw1Tg8OoIU-6H8PM6HaRgOsROmA46YbgEtLznteFjWJPmMEjcfg5nhfboiJa8K1DFKYOFm/s800/foundry%2520%2520ingot%2520tray.jpg" target="_blank"><img alt="making of L bar ingot mould" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMqvZXyknG0npTLapuf0jiohxPXpTPcZc8mP4_gTmRGUR8HDLdLl3nsaK5PtCPUDOWBBIs2Dqw1Tg8OoIU-6H8PM6HaRgOsROmA46YbgEtLznteFjWJPmMEjcfg5nhfboiJa8K1DFKYOFm/s1600/foundry++ingot+tray.jpg" target="_blank" title="L bar ingot tray" width="90" /></a></span></td> <td><span style="font-family: Arial, Helvetica, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqrdGX8Vvvgc2Om6zEHjPDs8WDx7nAudPFfn0h3vWZlU_TfFhdH2x8pP7Tv0PLSl-butFTW7XVNtKXKaEGdzSn8TEb_52xWff20njV9yfhqFOiGkeEmoLNZRT_jOEy3xXlw9J3Qv8dwsRK/s800/foundry%2520ingot%2520tray%25201.jpg" target="_blank"><img alt="first use of ingot mould" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqrdGX8Vvvgc2Om6zEHjPDs8WDx7nAudPFfn0h3vWZlU_TfFhdH2x8pP7Tv0PLSl-butFTW7XVNtKXKaEGdzSn8TEb_52xWff20njV9yfhqFOiGkeEmoLNZRT_jOEy3xXlw9J3Qv8dwsRK/s1600/foundry+ingot+tray+1.jpg" target="_blank" title="aluminum ingots" width="90" /></a></span></td> <td><span style="font-family: Arial, Helvetica, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0kYcmuKS1WEzUxmVa_2BZ75QOd3CCte-Bdfek6pnEGLPV1-xxQ97RYkDSqgXMdapcG51I4vk7pKzVHHkyQkdpPhMeB8wh20mPrRV9Ym5OjDjLIMz2kWncHKPvRS2q8HmNUP6vER5TTiiA/s800/foundry%2520ingot%2520tray%25202.jpg" target="_blank"><img alt="easy to remove aluminum ingots" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0kYcmuKS1WEzUxmVa_2BZ75QOd3CCte-Bdfek6pnEGLPV1-xxQ97RYkDSqgXMdapcG51I4vk7pKzVHHkyQkdpPhMeB8wh20mPrRV9Ym5OjDjLIMz2kWncHKPvRS2q8HmNUP6vER5TTiiA/s1600/foundry+ingot+tray+2.jpg" target="_blank" title="new aluminum ingots" width="90" /></a></span></td> <td><span style="font-family: Arial, Helvetica, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPTx4P-M69p9D9YHSyv1HtoqiZ5BKUB-lFD1YkT6kJ0xrf-IBeTxykbDBeYPNBHE2tIThnovRLZe-sjrzg2HRzX5As19DivHY9_rAyBlzkCNuJ06VajuHuv2TSBBpoGCigMZTv4DU1UKAb/s800/foundry%2520aluminum%2520ingots.jpg" target="_blank"><img alt="triangular aluminum ingots make it easy to stack pile them" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMqDyFoX7wLtXNS_nATLvJxqxLvqta1iZJsMH8crPbLlQWTBzqmSHjNocjXcXqBSZUepYDyzu2kswhxjN2FB4K7kYUK1eeYYMRohT9QKVDlaFuil-oRn4wlXyS5iutr34OrcykewOo7T53/s1600/foundry+aluminum+ingots.jpg" target="_blank" title="stacking aluminum ingots" width="90" /></a></span></td> </tr>
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<div>
<span style="font-family: Arial, Helvetica, sans-serif;">I still didn't have time to finish my <a href="http://www.flamingfurnace.com/2012/05/aluminum-cope-and-drag-casting.html">aluminum flask project </a>at the moment I have only 4 parts complete and I have to sand cast 4 more. A good solution for temporary flask or just a cheap foundry flask is to make it out of timber. The flask could be made from scrap timber as long as the cope and drag of the flask align together. The size of the flask depends on the size of the object to be casted. Just remember the bigger the flask is the more casting sand and weight you will have to take into consideration. For large wood flask it's recommended to create some sort of ribs inside the flask either by nailing some sort of strip or to make grooves in the inside of the flask. What ever works is good if it keeps the sand in the flask ;-)</span></div>
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<tr> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLWYGMQTR14C9sbiPmbyDch7jdu2W7k-IuAg3nc_J89Mtr-HfIqP-v2TW8pn415QQ-ZP0x-QLGW3K1nbLGsXU43ZO6M84_CX9hW0VwckBhrKIQdyjBrEOkrXXUQxg1mcBmpS_xrw4cK8Z5/s800/foundry%2520flask%2520cope%2520and%2520drag.JPG" target="_blank"><img alt="open wooden foundry flask" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLWYGMQTR14C9sbiPmbyDch7jdu2W7k-IuAg3nc_J89Mtr-HfIqP-v2TW8pn415QQ-ZP0x-QLGW3K1nbLGsXU43ZO6M84_CX9hW0VwckBhrKIQdyjBrEOkrXXUQxg1mcBmpS_xrw4cK8Z5/s1600/foundry+flask+cope+and+drag.JPG" target="_blank" title="foundry flask " width="100" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXdR5aV-wXtN6ya6KXiaahvZGkqoaNAlNiDpVkgT7C_0aZ3eM-QJ5KGIS2tlnZuIrNt9glWaKsmoGABKKGcGrtX2kbghUPZdvYvNCzyFxAJPqhOzcaVshn4OpweG2Sfidovg_b1kvKpL-f/s800/foundry%2520flask.JPG" target="_blank"><img alt="foundry flask cope and drag closed" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXdR5aV-wXtN6ya6KXiaahvZGkqoaNAlNiDpVkgT7C_0aZ3eM-QJ5KGIS2tlnZuIrNt9glWaKsmoGABKKGcGrtX2kbghUPZdvYvNCzyFxAJPqhOzcaVshn4OpweG2Sfidovg_b1kvKpL-f/s1600/foundry+flask.JPG" target="_blank" title="wooden foundry flask" width="100" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWke3LoJBFfB7OFkrdpHrtKKwkIIthfvTiF86TeAQq8M-KxHHylqVsY0y1Pm1IalWDA-f_S0ilTkUiTwSPnuKv4pOSVSqjPmNi_g-6hA2AEfFoN8BylMaeyy-WAmcl__YhqijvJ6-6hVMT/s800/foundry%2520wooden%2520flask.JPG" target="_blank"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWke3LoJBFfB7OFkrdpHrtKKwkIIthfvTiF86TeAQq8M-KxHHylqVsY0y1Pm1IalWDA-f_S0ilTkUiTwSPnuKv4pOSVSqjPmNi_g-6hA2AEfFoN8BylMaeyy-WAmcl__YhqijvJ6-6hVMT/s1600/foundry+wooden+flask.JPG" target="_blank" width="100" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgktVSlq6Mx7GwnWuMHLcx9b-xgng-D7QJGuJemI_tYC-p7Y38BqFB3YQqp2H3ACxMDZs6Rd4fPCjeajKPoB8OM4mvJi9VrJI0rZ_242gw3ubzlzt3nWb8xz_ufqx7qwkmXua4Sqd1qbBNC/s800/wooden%2520foundry%2520flask.jpg" target="_blank"><img alt="different sizes of foundry flasks" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgktVSlq6Mx7GwnWuMHLcx9b-xgng-D7QJGuJemI_tYC-p7Y38BqFB3YQqp2H3ACxMDZs6Rd4fPCjeajKPoB8OM4mvJi9VrJI0rZ_242gw3ubzlzt3nWb8xz_ufqx7qwkmXua4Sqd1qbBNC/s1600/wooden+foundry+flask.jpg" target="_blank" title="wooden flasks" width="100" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiiSgXwk_KMtDXtxKfLJ_VawGPg7_8FEzhdR2TEbxeh3nHLLc3lTfUTQaWhDMJE2sIN1CTsnKOzw9mbUbiW4ywdcLOUXyZCAmSAXCPe5jor0FiXIUdq0YatgvYMiMFL-2-c3dVQ-8LKVUvf/s800/molten%2520aluminum%2520in%2520foundry%2520crucible.jpg" target="_blank"><img alt="first use of large metal crucible" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiiSgXwk_KMtDXtxKfLJ_VawGPg7_8FEzhdR2TEbxeh3nHLLc3lTfUTQaWhDMJE2sIN1CTsnKOzw9mbUbiW4ywdcLOUXyZCAmSAXCPe5jor0FiXIUdq0YatgvYMiMFL-2-c3dVQ-8LKVUvf/s1600/molten+aluminum+in+foundry+crucible.jpg" target="_blank" title="foundry in action" width="100" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9mIvbFxiZGaDlQMQfN3srdIc7euqhXvkkJzpIwbQcyLFIXxl_eyyWIEgZEA9VVAW8pUH5k4-rYtSG5MW6ZAy9jQuQ0EVpCSDb0M8Gi4Uvx9ZsO8O-mOHIMo4c2KV8mLziXUL4n43dsVFk/s800/molten%2520aluminum%2520in%2520ingot%2520tray.JPG" target="_blank"><img alt="shiny molten metal aluminum ingots" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9mIvbFxiZGaDlQMQfN3srdIc7euqhXvkkJzpIwbQcyLFIXxl_eyyWIEgZEA9VVAW8pUH5k4-rYtSG5MW6ZAy9jQuQ0EVpCSDb0M8Gi4Uvx9ZsO8O-mOHIMo4c2KV8mLziXUL4n43dsVFk/s1600/molten+aluminum+in+ingot+tray.JPG" target="_blank" title="aluminum ingots" width="100" /></a></td> </tr>
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<span style="font-family: Arial, Helvetica, sans-serif;">The last two images are the main components needed to run a homemade foundry. In my next posts I will cover the issues like how to polish aluminum parts and about different sources of aluminum for the backyard metal caster.</span><br />
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<tr> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHkTQo_LPnivtfe2ZylisBnFCiw02vm3-uDuCcmZv6zPchiW29jZx0YqxIFNkUXjXgu8BgdxX5kugGl3ki8VEjuHwJBF2sKsz_hKYUZXGG8bsOZ2VLWHZTs2nVhzXt08yLRwIuOsML08yT/s1600/aluminum+foundry+crucible+tools+burner+ingot+tray+green+sand.jpg" imageanchor="1"><img alt="foundry tools, burner, ingots, green sand" border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHkTQo_LPnivtfe2ZylisBnFCiw02vm3-uDuCcmZv6zPchiW29jZx0YqxIFNkUXjXgu8BgdxX5kugGl3ki8VEjuHwJBF2sKsz_hKYUZXGG8bsOZ2VLWHZTs2nVhzXt08yLRwIuOsML08yT/s200/aluminum+foundry+crucible+tools+burner+ingot+tray+green+sand.jpg" title="foundry full setup" width="200" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyOIisl4tXI9otyVgfnq_9EOya6wFkzt9og_7CRxSviw-T9iD1RPUJ9-ZeMLhbKSXgP7EKEZrWtGbZysTyrRCrEHxsv_EqxP9u8asXszJtgdwvSO5229DpGNMl4wFjPWmiUiEw8CcVS7UF/s1600/aluminum+foundry+crucible+tools+burner+ingot+tray.jpg" imageanchor="1"><img alt="foundry tools and aluminum ingots" border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyOIisl4tXI9otyVgfnq_9EOya6wFkzt9og_7CRxSviw-T9iD1RPUJ9-ZeMLhbKSXgP7EKEZrWtGbZysTyrRCrEHxsv_EqxP9u8asXszJtgdwvSO5229DpGNMl4wFjPWmiUiEw8CcVS7UF/s200/aluminum+foundry+crucible+tools+burner+ingot+tray.jpg" title="open foundry setup" width="200" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhayjdkFzUlWhfnOjt81T5n8Xi-MtwHWmXLj3mPNeORdreZFxG7YzYRQh646Z3VQzOqNnPnrOrfICD3zxY3FJlLCehaH6DqYT_LD6JQjh6KLICs7XJHFlmJH4ygYDqSWj3f96JT8ORUGKOs/s800/foundry%2520aluminum%2520ingots.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhayjdkFzUlWhfnOjt81T5n8Xi-MtwHWmXLj3mPNeORdreZFxG7YzYRQh646Z3VQzOqNnPnrOrfICD3zxY3FJlLCehaH6DqYT_LD6JQjh6KLICs7XJHFlmJH4ygYDqSWj3f96JT8ORUGKOs/s200/foundry%2520aluminum%2520ingots.jpg" width="200" /></a></td></tr>
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<span style="font-family: Georgia, Times New Roman, serif;">Happy casting ;-)</span></div>
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<br />FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-17667249120712234122012-11-17T11:50:00.000-08:002013-04-16T03:55:01.678-07:00Sand Casting new ball handleI decided to upgrade my kitchen stool handle by changing it to a large aluminum ball handle. Last year I sand casted two aluminum balls, I used my sons plastic toy ball as a <a href="http://www.flamingfurnace.com/2011/02/sand-casting-terminology.html">pattern</a> ;-)<br />
Since then I didn't really have a use for those aluminum balls but I kept them knowing I would find some use for them. In this first set of images you can see the sand casting process. I used <a href="http://www.flamingfurnace.com/2011/02/sand-casting-terminology.html">petrobond (oil bonded sand)</a>.<br />
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<tr> <td></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIras07-BLKD6qX72kJOnm478x6oOhAhla7kiw0dyUu_vR6ruZqa987T-73-OxLqMpRWi-kkimX1qqcgotsixRPsOQcQRHZCjRteHFEP3uHrd3k473zzuFxXg62z-HBm8Ggm5Qt6Ao0sAC/s800/foundry%2520sand%2520casting%2520aluminum%2520ball%2520pattern%25202.JPG"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIras07-BLKD6qX72kJOnm478x6oOhAhla7kiw0dyUu_vR6ruZqa987T-73-OxLqMpRWi-kkimX1qqcgotsixRPsOQcQRHZCjRteHFEP3uHrd3k473zzuFxXg62z-HBm8Ggm5Qt6Ao0sAC/s200/foundry+sand+casting+aluminum+ball+pattern+2.JPG" width="150" /></a><span id="goog_1980732349"></span><span id="goog_1980732350"></span><a href="http://www.blogger.com/"></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNfbZRD-nRTXBNsg3OI1dCK_GFe70kElEaSU0zUzkyZlNTrr9JNneVXwSwGOkhW8p__gDX1Dz8ca0uMCJGBN9uVWvi82xZS38P3SK8jMbhsDC9E5YLVeCg28SB4stFGrbP8i1iVTp-KT0h/s800/foundry%2520sand%2520casting%2520aluminum%2520ball%2520pattern%25201.JPG"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNfbZRD-nRTXBNsg3OI1dCK_GFe70kElEaSU0zUzkyZlNTrr9JNneVXwSwGOkhW8p__gDX1Dz8ca0uMCJGBN9uVWvi82xZS38P3SK8jMbhsDC9E5YLVeCg28SB4stFGrbP8i1iVTp-KT0h/s1600/foundry+sand+casting+aluminum+ball+pattern+1.JPG" width="150" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVQwqme-aC7DnkNxhtEWxVg9pQOxtjKufARFDsMtsb_k1ZXngNgYAVBY5r26NjQ0EFjpDGN6oeFAdQRnabxzjozcmWoA40sVIPhCu1NTiaCUKzEb_FUN3wcwP8dVTDYsUrjKPYUKuB4SyN/s800/sand%2520casting%2520ball%2520mold%2520impression.JPG"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVQwqme-aC7DnkNxhtEWxVg9pQOxtjKufARFDsMtsb_k1ZXngNgYAVBY5r26NjQ0EFjpDGN6oeFAdQRnabxzjozcmWoA40sVIPhCu1NTiaCUKzEb_FUN3wcwP8dVTDYsUrjKPYUKuB4SyN/s1600/sand+casting+ball+mold+impression.JPG" width="150" /></a></td></tr>
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Creating the sand mold impression of the balls was a very simple process, however its not a split pattern so it took a bit longer to carve the sand up to the middle of the ball.<br />
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<tr> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkWhqma_41H2S6xBSe_rOLE0BmbIiBn0DARI7ObjL-e1vkpCtz9gsb4Nmop1zTWJ0Fry3JqaqSkGmPCeZDdVXoVaTmYdiH9FtyiRWAXEt8qC6ItBDnGAl5hHdERK5SNxFzZi0ojjKGDx62/s800/foundry%2520flask%25201.JPG"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkWhqma_41H2S6xBSe_rOLE0BmbIiBn0DARI7ObjL-e1vkpCtz9gsb4Nmop1zTWJ0Fry3JqaqSkGmPCeZDdVXoVaTmYdiH9FtyiRWAXEt8qC6ItBDnGAl5hHdERK5SNxFzZi0ojjKGDx62/s1600/foundry+flask+1.JPG" width="150" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg45fOydkHXbhZVHxymcC3E5vRMs7LMc6R3gMeLQHH2v0rdS_vErn2cdBDZHrnKJ9FpDmGOu_3GtPHQHHITMHyM8eW0Adiwl351V6ZJ0GzLaa2XnHbCTAbb0oWmg1Tcv2zIG7Ov4JqWoBF1/s800/foundry%2520flask%25203.JPG"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg45fOydkHXbhZVHxymcC3E5vRMs7LMc6R3gMeLQHH2v0rdS_vErn2cdBDZHrnKJ9FpDmGOu_3GtPHQHHITMHyM8eW0Adiwl351V6ZJ0GzLaa2XnHbCTAbb0oWmg1Tcv2zIG7Ov4JqWoBF1/s200/foundry+flask+3.JPG" width="150" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyqUrCbRvSSWpJMQNJZSHxrG2lG5E9ISLZu-Sj_RV2YU4311yA8i3hRRPDkHzrZo3yFyTXHE3z5EXp8NWRKUXsadzNvtYKpQVi0zcCtObZCAXrbGaNPqzNvNiZRdIqVXwCfO3OcibBJ5lW/s800/foundry%2520flask%25202.JPG"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyqUrCbRvSSWpJMQNJZSHxrG2lG5E9ISLZu-Sj_RV2YU4311yA8i3hRRPDkHzrZo3yFyTXHE3z5EXp8NWRKUXsadzNvtYKpQVi0zcCtObZCAXrbGaNPqzNvNiZRdIqVXwCfO3OcibBJ5lW/s200/foundry+flask+2.JPG" width="150" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrAeCl3BXqL5TbIKwSyQIxaptkVpisLXkMJZkMXUcmdNE6XYaagTiahS2BbVwbfTgKhd8IwuHyAd1wwNqFA5Rt7i6T6kIKrRCCr1u9KN-pZU8HqO_v37T-Y5O4bvdjUQMV930oR1Y5iE1U/s800/aluminum%2520ball%2520sand%2520casting.JPG"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrAeCl3BXqL5TbIKwSyQIxaptkVpisLXkMJZkMXUcmdNE6XYaagTiahS2BbVwbfTgKhd8IwuHyAd1wwNqFA5Rt7i6T6kIKrRCCr1u9KN-pZU8HqO_v37T-Y5O4bvdjUQMV930oR1Y5iE1U/s200/aluminum+ball+sand+casting.JPG" width="150" /></a></td></tr>
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After the molten aluminum cooled down I opened the wooden flask and cut off the<a href="http://www.flamingfurnace.com/2011/02/sand-casting-terminology.html"> riser </a>with a hacksaw. Then I cleaned the extra aluminum using a metal file and an electric sander.<br />
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<tr> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_QBgF_tk1nn5EQfZ-LD9OCKI5LV6uZNzN6Qj74DDePYRQrQOwHoKj0URPplF0NBFfs96eD7YqdNCRO5npTtN60gfB9smOuG_-9Y1oHRzyNy4PkXadfYZg1xzTRqgoFeLFu6XYk_LaA3li/s800/aluminum%2520balls%2520foundry%2520sand%2520casting.JPG"><img 0="0" alt="after cleaning the aluminum balls" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_QBgF_tk1nn5EQfZ-LD9OCKI5LV6uZNzN6Qj74DDePYRQrQOwHoKj0URPplF0NBFfs96eD7YqdNCRO5npTtN60gfB9smOuG_-9Y1oHRzyNy4PkXadfYZg1xzTRqgoFeLFu6XYk_LaA3li/s200/aluminum+balls+foundry+sand+casting.JPG" title="aluminum balls" width="150" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8fvFlCdhea5Qavg8zHl4FXSeVyd3i12v-BO4P6I6C0vsnpwJZM548EhQeUwqozsUH5PkCPx4zudS8FAewLhyAoYjB2JpLyiz8yW_cf2UmSExdSpW80_mDV0eeLnCRwJSZNIJGNMgee51v/s800/small%2520aluminum%2520ball%2520sand%2520casting.JPG"><img 0="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8fvFlCdhea5Qavg8zHl4FXSeVyd3i12v-BO4P6I6C0vsnpwJZM548EhQeUwqozsUH5PkCPx4zudS8FAewLhyAoYjB2JpLyiz8yW_cf2UmSExdSpW80_mDV0eeLnCRwJSZNIJGNMgee51v/s200/small+aluminum+ball+sand+casting.JPG" width="150" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7NUeL3cOw0Rg1UtpbXUFFe8QHKNOMVZoLWOFrHStQpqaOHAnIZhp8Y0g0xUYBEL1D9TKjyGxPX-ZX7EKEoTQp-HS1egH4Ixx89TUi4_gEfmMby6TVJGuPZYceK8FwANd7sozRjtydG_LF/s800/aluminum%2520balls%2520sand%2520casting.JPG"><img 0="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7NUeL3cOw0Rg1UtpbXUFFe8QHKNOMVZoLWOFrHStQpqaOHAnIZhp8Y0g0xUYBEL1D9TKjyGxPX-ZX7EKEoTQp-HS1egH4Ixx89TUi4_gEfmMby6TVJGuPZYceK8FwANd7sozRjtydG_LF/s200/aluminum+balls+sand+casting.JPG" width="150" /></a></td></tr>
</tbody></table>
After cleaning the aluminum ball I used my tap and die set to make a threaded hole in the aluminum ball. Once that was done I polished it and attached it into place.</div>
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<tr><td></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiX_qoePEAAKIUhs2KivHzZjgCiuXhpEqveXw8z3MY1-PBIaOlD-q8PIpwDYoIVr8yOOK3Q0H3W6CCBT_W8FnhJ-evgI_3GQxf2U79RIL5Daf4i0pfAQxURPXFdAaj_xkhUJpdCnv4UCxrN/s800/threaded%2520hole%2520in%2520aluminm%2520ball%2520foundry%2520sand%2520casting.JPG"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiX_qoePEAAKIUhs2KivHzZjgCiuXhpEqveXw8z3MY1-PBIaOlD-q8PIpwDYoIVr8yOOK3Q0H3W6CCBT_W8FnhJ-evgI_3GQxf2U79RIL5Daf4i0pfAQxURPXFdAaj_xkhUJpdCnv4UCxrN/s200/threaded+hole+in+aluminm+ball+foundry+sand+casting.JPG" width="140" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKteykrKAkuB3mXqEIml_kIqkRpbM6Y5I-dX_oiYD6C7d1x8p-iHiTW0hDlJshH8bitHZt3ZxD2n-hipwUXmcJE4-3PARz1Z_hwrHP1pdw1R0n0YdagFaInPEfg9xYrvEsLIpotfjCEq2V/s800/aluminum%2520ball%2520after%2520polish%2520and%2520threaded%2520hole%2520is%2520made.JPG"><img alt="sand casting aluminum ball" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKteykrKAkuB3mXqEIml_kIqkRpbM6Y5I-dX_oiYD6C7d1x8p-iHiTW0hDlJshH8bitHZt3ZxD2n-hipwUXmcJE4-3PARz1Z_hwrHP1pdw1R0n0YdagFaInPEfg9xYrvEsLIpotfjCEq2V/s1600/aluminum+ball+after+polish+and+threaded+hole+is+made.JPG" title="home foundry casting" width="140" /></a></td> <td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijya51lR6rT44Hyu5OP8VkIOfjYW1a1MZMY5uaVFFpB0xaN24YFoL7TLYfEg01tLhmDUVu7TvD09f2M4ZiF6Ez4Ph5uWy4bxAmSKvzaXTrtoH8nt3NbDzqRgC9VUEWRgtHSzoiPLMPNCgf/s800/aluminum%2520ball%2520handle%2520foundry%2520sand%2520casting.JPG"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijya51lR6rT44Hyu5OP8VkIOfjYW1a1MZMY5uaVFFpB0xaN24YFoL7TLYfEg01tLhmDUVu7TvD09f2M4ZiF6Ez4Ph5uWy4bxAmSKvzaXTrtoH8nt3NbDzqRgC9VUEWRgtHSzoiPLMPNCgf/s1600/aluminum+ball+handle+foundry+sand+casting.JPG" width="140" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRSkaw2-7oxOUxwMpWKvUWRvKCr5Tgff8KjxfsKX3ioe6H8mpN8Lss4Ba_FDaH9aLF8slLoHcH-tBJkTipxRVjmZ9vrgT3SXWuQ8XDzm_ER8eHzmGj2RYOu3nf3ugS4Axg9WPrDfpdfGJi/s800/aluminum%2520ball%2520foundry%2520sand%2520casting.JPG"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRSkaw2-7oxOUxwMpWKvUWRvKCr5Tgff8KjxfsKX3ioe6H8mpN8Lss4Ba_FDaH9aLF8slLoHcH-tBJkTipxRVjmZ9vrgT3SXWuQ8XDzm_ER8eHzmGj2RYOu3nf3ugS4Axg9WPrDfpdfGJi/s200/aluminum+ball+foundry+sand+casting.JPG" target="_blank" width="140" /></a></td> </tr>
<tr><td></td> </tr>
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FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-48331519895748435162012-09-30T15:23:00.001-07:002012-12-28T17:40:30.372-08:00Sand casting paintball handleI get many emails from people that are interested in creating aluminum replica's from another objects.<br />
I got a request from one particular visitor who wanted to create a replica of a plastic paintball gun handle into an aluminum handle. I really enjoyed creating this part. The sand molding process was very basic and it was very easy to polish the finished product.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhfgWRzCodpyFLUWzUbb5XjH-6O4fMekefqM0Nzpf_D60JSkWA7tHegz2aH52_4E_D7CWvyTgGTIkVqN_C2Vt006NtTHPqpt8u4qFJyncTdgH6UIwGW8pOu2sYlPjZGjX8QtBd6KmmGyk2/s1600/aluminum+paintball+gun+handle.JPG"><img border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhfgWRzCodpyFLUWzUbb5XjH-6O4fMekefqM0Nzpf_D60JSkWA7tHegz2aH52_4E_D7CWvyTgGTIkVqN_C2Vt006NtTHPqpt8u4qFJyncTdgH6UIwGW8pOu2sYlPjZGjX8QtBd6KmmGyk2/s200/aluminum+paintball+gun+handle.JPG" width="150" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8sxyXQZKqw13fRu1pJe3bVKq2ArfYwx-gFTCLVMj6EV7Eg7-ew9LImYCNyNTiGRYmEYuqRrDKy1l6WcBe2BrcZ7wy89vDWJRxGoRY7LnSIRjbpl8ZZZk08iLV9HdB_8zel6eJn-MIgjK8/s1600/sand+casting+aluminum+paintball+gun+handle+2.JPG"><img border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8sxyXQZKqw13fRu1pJe3bVKq2ArfYwx-gFTCLVMj6EV7Eg7-ew9LImYCNyNTiGRYmEYuqRrDKy1l6WcBe2BrcZ7wy89vDWJRxGoRY7LnSIRjbpl8ZZZk08iLV9HdB_8zel6eJn-MIgjK8/s200/sand+casting+aluminum+paintball+gun+handle+2.JPG" width="150" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZKlSjaaNXk5qO2L2adQG8ouEGdT3vThC1ixykF17XW3kwBoVPATpC7pbhZ5yivhdojp2Qe4tLCE04qkkscJCojmv_sB8zxGRk6jmnzSYdKPPqMmo_uQbpmN6AbQBFHZ2f49A6Cut1ITkG/s1600/sand+casting+aluminum+paintball+gun+handle+3.JPG"><img border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZKlSjaaNXk5qO2L2adQG8ouEGdT3vThC1ixykF17XW3kwBoVPATpC7pbhZ5yivhdojp2Qe4tLCE04qkkscJCojmv_sB8zxGRk6jmnzSYdKPPqMmo_uQbpmN6AbQBFHZ2f49A6Cut1ITkG/s200/sand+casting+aluminum+paintball+gun+handle+3.JPG" width="150" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEduM_WG5t0lnwGx_j-woPbP-fd37XWVOmIYzEh1WaPsngQUCn2tA-6aCnvaVdkPm-YmK1l0R_hT7HFJlXAz-Bm1WIOyuHbDo3Rlm_rNeLInL6M6zm6P5Flo3Pl5KKBTmQzwzmQr7PJtB9/s1600/sand+casting+aluminum+paintball+gun+handle+1.JPG"><img border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEduM_WG5t0lnwGx_j-woPbP-fd37XWVOmIYzEh1WaPsngQUCn2tA-6aCnvaVdkPm-YmK1l0R_hT7HFJlXAz-Bm1WIOyuHbDo3Rlm_rNeLInL6M6zm6P5Flo3Pl5KKBTmQzwzmQr7PJtB9/s200/sand+casting+aluminum+paintball+gun+handle+1.JPG" width="150" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsHMOsrkbPbcXW3VBO0IiBExNJcwUDqVnJNS8pxhSKbYG7RaexffC7N6eLnT-Uw08jyDyYLYkya-FJh4PhyDeSjbAyeihmkdUqGKcRpVMRht7fQQ2wYlb26Tz8dxwc_qR0mGyxMr5sA68D/s1600/aluminum+paintball+gun+handle+with+riser.JPG"><img border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsHMOsrkbPbcXW3VBO0IiBExNJcwUDqVnJNS8pxhSKbYG7RaexffC7N6eLnT-Uw08jyDyYLYkya-FJh4PhyDeSjbAyeihmkdUqGKcRpVMRht7fQQ2wYlb26Tz8dxwc_qR0mGyxMr5sA68D/s200/aluminum+paintball+gun+handle+with+riser.JPG" width="150" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOIKl9rBiwaUrtbG7_fBl2dGhlDRTQfsaVfxyVr7IwkmkKHrxQUFrQqkyle0UKVP-q-QzTnKmiHSwb0d3Vyh5I0fwmV7_gRJz39L3XvlfIZkOAIL2_DMrv5C1HXFAHgid8xhUdNSH6y_CZ/s1600/aluminum+paintball+gun+handle+and+replica+2.JPG"><img border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOIKl9rBiwaUrtbG7_fBl2dGhlDRTQfsaVfxyVr7IwkmkKHrxQUFrQqkyle0UKVP-q-QzTnKmiHSwb0d3Vyh5I0fwmV7_gRJz39L3XvlfIZkOAIL2_DMrv5C1HXFAHgid8xhUdNSH6y_CZ/s200/aluminum+paintball+gun+handle+and+replica+2.JPG" width="150" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqEOutuNg9JnkPBjS6LR6CuVllDTPMakqfIHAiv8Ab4kY-UB72bu5v0jEVZUOUV3kT-tQFLUTsm3Voz47vGAIM10Qdo1YCD85B0F83XgtQhegwA8yBUYBfHQsP9Hwsupy0ZbuOwATyV0fe/s1600/aluminum+paintball+gun+handle+and+replica+1.JPG"><img border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqEOutuNg9JnkPBjS6LR6CuVllDTPMakqfIHAiv8Ab4kY-UB72bu5v0jEVZUOUV3kT-tQFLUTsm3Voz47vGAIM10Qdo1YCD85B0F83XgtQhegwA8yBUYBfHQsP9Hwsupy0ZbuOwATyV0fe/s200/aluminum+paintball+gun+handle+and+replica+1.JPG" width="150" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6jYEN0rTNLUPjanfOFXcGe5_lJ3Rdqc0KjIwXUrfCFaJFZXmq8uB0DPMbyDQIYGREO5gst7iG4XWqU1OatXdb4zT2mXTJD1T8jVBXXRI7Z42yT0iPRVsiBhnGuOXLUftmdvAUvesygxai/s1600/aluminum+paintball+gun+handle+and+replica+3.JPG"><img border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6jYEN0rTNLUPjanfOFXcGe5_lJ3Rdqc0KjIwXUrfCFaJFZXmq8uB0DPMbyDQIYGREO5gst7iG4XWqU1OatXdb4zT2mXTJD1T8jVBXXRI7Z42yT0iPRVsiBhnGuOXLUftmdvAUvesygxai/s200/aluminum+paintball+gun+handle+and+replica+3.JPG" width="150" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-13635489039067215252012-09-24T15:36:00.001-07:002012-09-24T15:36:41.531-07:00Electrolysis rust removal for a rusty pipe wrenchThis is just a few more images of another electrolysis de-rusting session.
I found this pipe wrench in a metal recycle bin and it looks like his former owner was a bit intimidated by the rusty look. Anyway after leaving the wrench in a derusting electrolysis bath over night the wrench is as good as new;-)
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgX9fy8RcpyyhcfgZY8Sfn2-6RNUIs_Kk7o6jnMZl6oGhG7INzoGZ5B_nTz7IoThFNX_MG8m0tg_K0Iwzx0GESvonXMEDKqxoNy8r0DK0B3bbSVCyw__ftC91BUnpMs0Y_qvrgREEqyDEy1/s1600/electrolysis+derusting+2.JPG" imageanchor="1"><img border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgX9fy8RcpyyhcfgZY8Sfn2-6RNUIs_Kk7o6jnMZl6oGhG7INzoGZ5B_nTz7IoThFNX_MG8m0tg_K0Iwzx0GESvonXMEDKqxoNy8r0DK0B3bbSVCyw__ftC91BUnpMs0Y_qvrgREEqyDEy1/s200/electrolysis+derusting+2.JPG" width="150" /></a>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbPuKHSqXXB5SHWCVPoYV9xLqCtyLBc_G3EcOr6wGuTjlnbnEiWwxtuGqRCOmoxBcVy9q0iIfl_7XRPUJr8-GVTJWElAoQI-JCQS1NzjwkQy18tHfMN1lQhZiyx5cZdB6o7rGPN0Hgq2vi/s1600/after+electrolysis+derusting+6.JPG" imageanchor="1"><img border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbPuKHSqXXB5SHWCVPoYV9xLqCtyLBc_G3EcOr6wGuTjlnbnEiWwxtuGqRCOmoxBcVy9q0iIfl_7XRPUJr8-GVTJWElAoQI-JCQS1NzjwkQy18tHfMN1lQhZiyx5cZdB6o7rGPN0Hgq2vi/s200/after+electrolysis+derusting+6.JPG" width="150" /></a>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiVlA1MB3vKrFetfRE_sLUDFTgLpqAT3Ejz4fmQAyzk48Nw_OzpeLWbWNemC2JyP7A08lMtH796uPC6WBmwtb552YGOOH9Z9RqHeN_78MPgoyOzIkrGK61U9g4JEVl6RDZIjezehlCi_Oq/s1600/electrolysis+derusting+3.JPG" imageanchor="1"><img border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiVlA1MB3vKrFetfRE_sLUDFTgLpqAT3Ejz4fmQAyzk48Nw_OzpeLWbWNemC2JyP7A08lMtH796uPC6WBmwtb552YGOOH9Z9RqHeN_78MPgoyOzIkrGK61U9g4JEVl6RDZIjezehlCi_Oq/s200/electrolysis+derusting+3.JPG" width="150" /></a>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSksDWK5IrgZ4L-6ljlEMHx4lbX9Jls5oBzkSGPEOl6PO8ulM554sY03SNTDtVpF-U3yl0f5O0xaj8L8P6Jncg5EUmnPv1tUKmNf0ip48-bw2l7lMAVsb7U0FwO8bzmQ1YweBSGnUZ2sjB/s1600/electrolysis+derusting+4.JPG" imageanchor="1"><img border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSksDWK5IrgZ4L-6ljlEMHx4lbX9Jls5oBzkSGPEOl6PO8ulM554sY03SNTDtVpF-U3yl0f5O0xaj8L8P6Jncg5EUmnPv1tUKmNf0ip48-bw2l7lMAVsb7U0FwO8bzmQ1YweBSGnUZ2sjB/s200/electrolysis+derusting+4.JPG" width="150" /></a>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8Xux8iH19XREsWap0sH3Em3M1G_Evy6ti1A8yi1hDHaCvTUaAzwq286bHCmkuMl6HkdbUatTO7o9XRYictl23asaA8DYedF4Qdv8LQEyYUg1V8jbdBvfJ1BqcSGPeBM5Ve8q9m4B7KLGj/s1600/electrolysis+derusting+5.JPG" imageanchor="1"><img border="0" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8Xux8iH19XREsWap0sH3Em3M1G_Evy6ti1A8yi1hDHaCvTUaAzwq286bHCmkuMl6HkdbUatTO7o9XRYictl23asaA8DYedF4Qdv8LQEyYUg1V8jbdBvfJ1BqcSGPeBM5Ve8q9m4B7KLGj/s200/electrolysis+derusting+5.JPG" width="150" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-83334149274012771322012-05-12T09:30:00.005-07:002013-04-17T13:39:36.828-07:00Cope and Drag casting projectThis is just a follow up post for my aluminum <a href="http://www.flamingfurnace.com/2011/02/sand-casting-terminology.html">foundry flask </a>casting progress.<br />
The first four parts of my <a href="http://www.flamingfurnace.com/2011/02/sand-casting-terminology.html">flask cope</a> are casted, at this stage I have to cast four more parts for the <a href="http://www.flamingfurnace.com/2011/02/sand-casting-terminology.html">drag</a> part. I made a video of the molten aluminum pouring process and the sand mould shake-out.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjL8rYadrXb_92_d3Y0aoQgL8_gfT7NxsqltVm8yFrx33GPO-b-6awg349EytorFz2fBu1KQOVKC9ELcDb-avnAmj2OFXssT7-9-OB9l-NOIgDgde_rgfgb4bs2jIWaq0A3Vd8-OHEX2g4Y/s1600/aluminum+foundry+flask+part.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5741689568307908242" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjL8rYadrXb_92_d3Y0aoQgL8_gfT7NxsqltVm8yFrx33GPO-b-6awg349EytorFz2fBu1KQOVKC9ELcDb-avnAmj2OFXssT7-9-OB9l-NOIgDgde_rgfgb4bs2jIWaq0A3Vd8-OHEX2g4Y/s200/aluminum+foundry+flask+part.jpg" style="cursor: hand; height: 95px; width: 132px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitevfdV_CCeLDZkZs1lkHTXhWgF50aIjxWyJM3_DSFhP87dGS_anMGzgSxTF1U0COAe1eT3D1KSOZOYKsgY6gG-S5W8oU5v31nw9JStVmkGTMqmMKFmCv68r5odmorUxsxBV-DoNdJoNEt/s1600/aluminum+foundry+pattern+and+aluminum+casting.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5741689577149717858" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitevfdV_CCeLDZkZs1lkHTXhWgF50aIjxWyJM3_DSFhP87dGS_anMGzgSxTF1U0COAe1eT3D1KSOZOYKsgY6gG-S5W8oU5v31nw9JStVmkGTMqmMKFmCv68r5odmorUxsxBV-DoNdJoNEt/s200/aluminum+foundry+pattern+and+aluminum+casting.jpg" style="cursor: hand; height: 94px; width: 126px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguiV0t_pwbx6fh6xy1JxxPrnY04XwPizIMqB2mCYjfOPnQSqSX8zZRB95iFJpLIC-rAr_DIVdDjo-b0tHJbvQF4Efj6BsOX115yxKHRUYjnrI89dJuqhacDJyag7uNeh6HMuy6BhDSsNIl/s1600/aluminum+foundry+flask+cope+parts+casted.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5741689563600462882" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguiV0t_pwbx6fh6xy1JxxPrnY04XwPizIMqB2mCYjfOPnQSqSX8zZRB95iFJpLIC-rAr_DIVdDjo-b0tHJbvQF4Efj6BsOX115yxKHRUYjnrI89dJuqhacDJyag7uNeh6HMuy6BhDSsNIl/s200/aluminum+foundry+flask+cope+parts+casted.JPG" style="cursor: hand; height: 94px; width: 137px;" /></a><br />
<iframe frameborder="0" height="315" src="http://www.youtube.com/embed/wAhDl6WQiGk?rel=0" width="420"></iframe>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-26825848140133552352012-04-12T16:33:00.009-07:002013-01-04T11:47:27.998-08:00Electrolysis - Rust Removal MethodThis post is not really related to metal casting it's just informative and interesting. I made this video showing a method of <span class="blsp-spelling-error" id="SPELLING_ERROR_0">de</span>-rusting. It is effective, cheap and every one can try this at home.<br />
In the images below you can see the the results of this process and how efficient it is.<br />
You can also see the electrolysis bucket that I made, I welded bolts to <span class="blsp-spelling-error" id="SPELLING_ERROR_1">rebars</span> using them as the sacrificial anodes and plywood as a base plate.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEir741Dld8HNisU1Ju31ErnuJkLTPmIz2JLQnCjh2h6hv7ORaFuhuByG91XrrGSTMQ-2bVIj4kyMndLiSVKDtcuMOyAnm6UKw7Q69pP61QuB0vgqNmMpALNOCGxqcSpuIDVVTOGZrCVXxm7/s1600/making+electrolysis+bucket.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5730668952357332882" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEir741Dld8HNisU1Ju31ErnuJkLTPmIz2JLQnCjh2h6hv7ORaFuhuByG91XrrGSTMQ-2bVIj4kyMndLiSVKDtcuMOyAnm6UKw7Q69pP61QuB0vgqNmMpALNOCGxqcSpuIDVVTOGZrCVXxm7/s200/making+electrolysis+bucket.jpg" style="cursor: hand; height: 77px; width: 119px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsEoAYfr3_TspcW-DJZDND50TgVuXkNGOxCz7wks8SzTdiQfNDyOMUE0nZDf8O1-oxF6VAHt4F4R25C6nQMjnkKXcInileLDT5MVRHjGVQNfOQLlbPpsf6t-FeUUPkQJvJPcPK8ixhg3MM/s1600/electrolysis+rust+removal+anodes.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5730668701898861842" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsEoAYfr3_TspcW-DJZDND50TgVuXkNGOxCz7wks8SzTdiQfNDyOMUE0nZDf8O1-oxF6VAHt4F4R25C6nQMjnkKXcInileLDT5MVRHjGVQNfOQLlbPpsf6t-FeUUPkQJvJPcPK8ixhg3MM/s200/electrolysis+rust+removal+anodes.jpg" style="cursor: hand; height: 79px; width: 123px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVtRS5Q5xFCw4EkmN5nNp7Gj4h-_Yl9bd-5VksFgwKd8HH3ktSUF9Ag3mRS6Fbt8QtfDoTHViXT9J5RME8RAGYKwg9YYhx1KqdqPy9CB-T-skrwRN6IvxQr5iSmPZ9Y4KaM_GoKybytJuX/s1600/electrolysis+rust+removal+wires.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5730668726958647058" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVtRS5Q5xFCw4EkmN5nNp7Gj4h-_Yl9bd-5VksFgwKd8HH3ktSUF9Ag3mRS6Fbt8QtfDoTHViXT9J5RME8RAGYKwg9YYhx1KqdqPy9CB-T-skrwRN6IvxQr5iSmPZ9Y4KaM_GoKybytJuX/s200/electrolysis+rust+removal+wires.jpg" style="cursor: hand; height: 77px; width: 94px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmLt-jsB5F5OvaULfrGC1KM2ABgNBH8xcW3JfOMbSp_5yLVxI4JZ_pMy8633RFdLwhljsEwUUDPpKJ8s8jBJusY6CVhHllwRYypKkgoUvEIuxILToP2_dYusNZqbiFv4mYiuhC-iJuf7Ab/s1600/electrolysis+rust+removal+parts.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5730668719458706018" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmLt-jsB5F5OvaULfrGC1KM2ABgNBH8xcW3JfOMbSp_5yLVxI4JZ_pMy8633RFdLwhljsEwUUDPpKJ8s8jBJusY6CVhHllwRYypKkgoUvEIuxILToP2_dYusNZqbiFv4mYiuhC-iJuf7Ab/s200/electrolysis+rust+removal+parts.jpg" style="cursor: hand; height: 78px; width: 116px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrR8t2aqP7CfQE4KFpa4d_i_36N7DbxdjGA0yZBCJ2xMjlniA-U8uPbml-oNJY39Y21B8HCyINcuwhm3kBkjZBgsSBEyv2Eff107y_73ZLPwSU6Jr7__tfVjwqpakl9Z0fi09xbQekD5wU/s1600/electrolysis+rust+removal+bucket.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5730668708449442162" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrR8t2aqP7CfQE4KFpa4d_i_36N7DbxdjGA0yZBCJ2xMjlniA-U8uPbml-oNJY39Y21B8HCyINcuwhm3kBkjZBgsSBEyv2Eff107y_73ZLPwSU6Jr7__tfVjwqpakl9Z0fi09xbQekD5wU/s200/electrolysis+rust+removal+bucket.jpg" style="cursor: hand; height: 80px; width: 100px;" /></a><br />
The next two images is the electrolysis <span class="blsp-spelling-error" id="SPELLING_ERROR_2">de</span>-rusting in action!<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4DdDMZOYlkRNOyCwlUGLGVH02xzmWqww6NP3z0a3HldXSFu-tiQyqbOIIxh6vFNayP6VOm-IjqmeBC6BfKQiWm34qsIiJ_OblXHL18ejkUHGQEl2E8Jv4ByV-XShyphenhyphenP5rhvkDWTS_chVbm/s1600/electrolysis+rust+removal+after+one+hour.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5730669892149129154" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4DdDMZOYlkRNOyCwlUGLGVH02xzmWqww6NP3z0a3HldXSFu-tiQyqbOIIxh6vFNayP6VOm-IjqmeBC6BfKQiWm34qsIiJ_OblXHL18ejkUHGQEl2E8Jv4ByV-XShyphenhyphenP5rhvkDWTS_chVbm/s200/electrolysis+rust+removal+after+one+hour.jpg" style="cursor: hand; height: 78px; width: 129px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKNow1wA4A7bBCLo91JRQ2hJJPysRTLB58o-uDJidHZdcu0xEGUGOGP2fwdQ2953yL21HmdZl0Dobzxk2nDcoUiPffn1TShjlnaXb3rYB4sG8YXUnGQYlUL2w-JS9xPlDqDjwX5QWFwFZx/s1600/electrolysis+rust+removal+rust+in+bucket.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5730669887189069458" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKNow1wA4A7bBCLo91JRQ2hJJPysRTLB58o-uDJidHZdcu0xEGUGOGP2fwdQ2953yL21HmdZl0Dobzxk2nDcoUiPffn1TShjlnaXb3rYB4sG8YXUnGQYlUL2w-JS9xPlDqDjwX5QWFwFZx/s200/electrolysis+rust+removal+rust+in+bucket.jpg" style="cursor: hand; height: 81px; width: 118px;" /></a><br />
This images are the before and after using the electrolysis rust removal method.<br />
bringing some rusty objects back to life.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmYJaXsH16RtJPlY76nYT147s3Z4jlc1_zmdgPqe8RgwC-NRPLXnctMCXlFjWlzNzIHst0cWvan5hbXkpwbrDiDjjudvfv7yKOdPxBYc43QbjFKew21gO5IkQca-r6vIc_xNIcqWCwBsbV/s1600/Electrolysis+rust+removal.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5730670809356416162" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmYJaXsH16RtJPlY76nYT147s3Z4jlc1_zmdgPqe8RgwC-NRPLXnctMCXlFjWlzNzIHst0cWvan5hbXkpwbrDiDjjudvfv7yKOdPxBYc43QbjFKew21gO5IkQca-r6vIc_xNIcqWCwBsbV/s200/Electrolysis+rust+removal.JPG" style="cursor: hand; height: 84px; width: 131px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhm3KDQLuyk2HRmH1XU2QHw2cuzMsB2S-k5CcG895OT6xeytGysUIkk-ULCJIJOcemzWOJq3_tdA83P81Os_KCF97a7pvLEfmqMgNUsDNm9J9FJzsN19umfTdU_wYBByVPNu4ksalc7-nJc/s1600/Electrolysis+rust+removal+5+before+and+after.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5730670801189927218" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhm3KDQLuyk2HRmH1XU2QHw2cuzMsB2S-k5CcG895OT6xeytGysUIkk-ULCJIJOcemzWOJq3_tdA83P81Os_KCF97a7pvLEfmqMgNUsDNm9J9FJzsN19umfTdU_wYBByVPNu4ksalc7-nJc/s200/Electrolysis+rust+removal+5+before+and+after.JPG" style="cursor: hand; height: 82px; width: 123px;" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEha76hd90EVgv2HAAn_9mwCsc81B2fNYC14j8cUarsq2ss9z0RlBMNPZuDel2bGUwLMX7-P-TSo9NJ5Tz4E14uYvvvMBkDEyYe-Af5wpx_FdepM_NtUV5wIHOD8dH1cWc03PDClk7csPu36/s1600/Electrolysis+rust+removal+2.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5730670795109368690" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEha76hd90EVgv2HAAn_9mwCsc81B2fNYC14j8cUarsq2ss9z0RlBMNPZuDel2bGUwLMX7-P-TSo9NJ5Tz4E14uYvvvMBkDEyYe-Af5wpx_FdepM_NtUV5wIHOD8dH1cWc03PDClk7csPu36/s200/Electrolysis+rust+removal+2.JPG" style="cursor: hand; height: 79px; width: 116px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1fCLLguEs3d4IFTGRqlXx8N260Livfy0JszzNCTJPKcE5K60m-FvQhYMBo7DYxWaq_15Sc3YdFRzXqltPnd1m8U6C974SCLviG6WN-CaeesErid4RHChmqRP3sts2jbKErttpuYmgNR4S/s1600/heavy+rust++bolt+nuts+before+electrolysis+rust+removal.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5730671814326418034" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1fCLLguEs3d4IFTGRqlXx8N260Livfy0JszzNCTJPKcE5K60m-FvQhYMBo7DYxWaq_15Sc3YdFRzXqltPnd1m8U6C974SCLviG6WN-CaeesErid4RHChmqRP3sts2jbKErttpuYmgNR4S/s200/heavy+rust++bolt+nuts+before+electrolysis+rust+removal.jpg" style="cursor: hand; height: 81px; width: 113px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEik-BVB3cCIlccFRmOrGDRCWf4hvixqBssBjnobPF3V6haGt6YkBFN7rTOvTXzli1yxxyA8M73y5OswaMBNSCbMWN5pswjo0UxRfWTwDi04StATXqEiyLPUZd_VN_FIBAEH6wmLcCiE-GcK/s1600/nuts+and+bolts+after+electrolysis+rust+removal.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5730670823364080498" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEik-BVB3cCIlccFRmOrGDRCWf4hvixqBssBjnobPF3V6haGt6YkBFN7rTOvTXzli1yxxyA8M73y5OswaMBNSCbMWN5pswjo0UxRfWTwDi04StATXqEiyLPUZd_VN_FIBAEH6wmLcCiE-GcK/s200/nuts+and+bolts+after+electrolysis+rust+removal.JPG" style="cursor: hand; height: 84px; width: 114px;" /></a> <span style="font-size: 0;"></span><br />
This is the video I made showing how to preform the electrolysis rust removal from a-z.<br />
Enjoy ;-)<br />
<iframe frameborder="0" height="315" src="http://www.youtube.com/embed/AQNvhUYqCkw?rel=0" width="420"></iframe>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-34351925206815924662012-04-05T16:18:00.008-07:002013-01-04T11:48:49.832-08:00Casting a new foundry flask (Part II)Yesterday I casted the second pattern of my new aluminum foundry flask. The first attempt of the sand moulding failed. I had to improve the angle/draft around the patterns handle section. After using more filler, sanding it and then finishing with a coat of varnish.<br />
The angle filler adjustment did the job and the sand mould second attempt was very good. I used again my homemade green sand and the aluminum casting was satisfactory.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1oFWq8L_HNFMPox2I7Y8Q-RO2YjQnfPsNrZHCKkJTTQvISmkze952BNm15673pOq99kdTwbbyJ-EecQJD561WHyjFDoNITSnpnFVcijtx6rrLidcqGGNmNKjEx0ZruCpwfutLchCQ4QmX/s1600/aluminum+flask+handle+part.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5728061845667663986" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1oFWq8L_HNFMPox2I7Y8Q-RO2YjQnfPsNrZHCKkJTTQvISmkze952BNm15673pOq99kdTwbbyJ-EecQJD561WHyjFDoNITSnpnFVcijtx6rrLidcqGGNmNKjEx0ZruCpwfutLchCQ4QmX/s200/aluminum+flask+handle+part.jpg" style="cursor: hand; height: 86px; width: 130px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRBJ1QfggjDYwJJaqJhUkhpuX3ATaRmkTqiRaHVCdsNNxRMqFA3jTVMeHVBwvQ2NMY38hKN-gS50qPeWHzbQC2-tpZkDJ3EWgx8CfDrpeOVZ2_sVy07V89HpgNeKNv75wdxDzMjgadjeqY/s1600/aluminum+flask+mould+with+sprue+and+riser.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5728061851382905170" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRBJ1QfggjDYwJJaqJhUkhpuX3ATaRmkTqiRaHVCdsNNxRMqFA3jTVMeHVBwvQ2NMY38hKN-gS50qPeWHzbQC2-tpZkDJ3EWgx8CfDrpeOVZ2_sVy07V89HpgNeKNv75wdxDzMjgadjeqY/s200/aluminum+flask+mould+with+sprue+and+riser.jpg" style="cursor: hand; height: 87px; width: 129px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLL2Tedr3Ef_EAIF_PTa_XDFOuFq0aMfKSYCidCYl76R8Py9Vhi7zMHWiXxUnAaP8_C9Dvd85QvCSeWpRVdD0ne37Sjx89rP5MWZW1KfqFPqGQ6nEnkMQgMxgFDOaMND5LUk7nS150xb3O/s1600/aluminum+sand+moulding+ready+for+shake+out.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5728061862431408370" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLL2Tedr3Ef_EAIF_PTa_XDFOuFq0aMfKSYCidCYl76R8Py9Vhi7zMHWiXxUnAaP8_C9Dvd85QvCSeWpRVdD0ne37Sjx89rP5MWZW1KfqFPqGQ6nEnkMQgMxgFDOaMND5LUk7nS150xb3O/s200/aluminum+sand+moulding+ready+for+shake+out.jpg" style="cursor: hand; height: 85px; width: 119px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgo9QpRIXm5sZutAGC73ex4z2pPvZvOy00mWPWfMF-gdI-QYXJjZ38it1G2UDdWXbkog4O6H_EpNM0f-B90nA15ErVRGD10QmskhmZOx9zG0Pye2p6VvU4LwYyBmP1ZxZYb_9HbOhHOGzx/s1600/aluminum+foundry+flask+casting.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5728061853776935234" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgo9QpRIXm5sZutAGC73ex4z2pPvZvOy00mWPWfMF-gdI-QYXJjZ38it1G2UDdWXbkog4O6H_EpNM0f-B90nA15ErVRGD10QmskhmZOx9zG0Pye2p6VvU4LwYyBmP1ZxZYb_9HbOhHOGzx/s200/aluminum+foundry+flask+casting.jpg" style="cursor: hand; height: 87px; width: 118px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijwaiVdi5gAga9TMKanVK-OZYM-ZXi7C8UZcw6sW-DkGu8IujGdcBSVB2UaBV6ExUee9wE6B0cBb_0UrKgnTiOkqwVXUxH_U2T2gnQ3SSGGT_gC3LN2aHVDgNc7fUjJ-btokGoo5B9Ok7I/s1600/aluminum+flask+good+casting.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5728061843513854162" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijwaiVdi5gAga9TMKanVK-OZYM-ZXi7C8UZcw6sW-DkGu8IujGdcBSVB2UaBV6ExUee9wE6B0cBb_0UrKgnTiOkqwVXUxH_U2T2gnQ3SSGGT_gC3LN2aHVDgNc7fUjJ-btokGoo5B9Ok7I/s200/aluminum+flask+good+casting.jpg" style="cursor: hand; height: 89px; width: 135px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_XCpAIdtlQPGS1FejNC_qQ1FQk2x7EnyNTUjaQLdZ6NQiwTVoKC6jSVb_m1KfxLXYiWhu_h8KsTsZpOzJufjczTO52oORKSq1eLZf9s58uHrooy_D5lS7sofOOaO1BCiYLojOCNCqbbGX/s1600/foundry+flask+and+pattern.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5728062086320116242" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_XCpAIdtlQPGS1FejNC_qQ1FQk2x7EnyNTUjaQLdZ6NQiwTVoKC6jSVb_m1KfxLXYiWhu_h8KsTsZpOzJufjczTO52oORKSq1eLZf9s58uHrooy_D5lS7sofOOaO1BCiYLojOCNCqbbGX/s200/foundry+flask+and+pattern.jpg" style="cursor: hand; height: 80px; width: 118px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvn92h-W8kM2oc9k9VUIGVRAwJ-HSS2fgDApEq4_-0b78e9LnWJJ69zfnhFQdoh-d8RC0wzmH8mlaDGtLuFdEca4f1bbV77GpDaLOC2HbG8D9hbUJTg7tuF4gfkUZhYd3HhEBGoLagij9I/s1600/foundry+flask+parts.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5728062097141308514" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvn92h-W8kM2oc9k9VUIGVRAwJ-HSS2fgDApEq4_-0b78e9LnWJJ69zfnhFQdoh-d8RC0wzmH8mlaDGtLuFdEca4f1bbV77GpDaLOC2HbG8D9hbUJTg7tuF4gfkUZhYd3HhEBGoLagij9I/s200/foundry+flask+parts.jpg" style="cursor: hand; height: 82px; width: 117px;" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-61891315049230663382012-04-03T07:18:00.012-07:002013-01-04T11:49:38.815-08:00Sand casting new foundry flask (Part I)This is a new video I made showing the sand moulding process of my future foundry flask. In the video I made you will see the first part of the aluminum flask. I have 7 more parts to cast before it's ready for use.<br />
This casting was made using my <a href="http://www.youtube.com/watch?v=vo1vcJG4E94">homemade green sand</a>. No need for very fine casting details it's just a sand box after all ;-)<br />
<em><u>This is my sketchup design:</u></em><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwPg2SQERTL3OW6kz_h7YjzOGxrA9GUgb_Kr1bG_VUmrOldfkSnemQL-1IvGF9k3OBU_ftCP8gTMfhkpmKvk4YjJOABQfKgrwPrD5XcpL1BauFmj47_6NaEm-SuX4e40ZVQUZ9zisoFuf6/s1600/aluminum+foundry+flask+xray+view.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5727188897869743538" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwPg2SQERTL3OW6kz_h7YjzOGxrA9GUgb_Kr1bG_VUmrOldfkSnemQL-1IvGF9k3OBU_ftCP8gTMfhkpmKvk4YjJOABQfKgrwPrD5XcpL1BauFmj47_6NaEm-SuX4e40ZVQUZ9zisoFuf6/s200/aluminum+foundry+flask+xray+view.jpg" style="cursor: hand; height: 78px; width: 126px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXLzEzhCE2WIocLMGiDXl8KMjmMxlyuIUOmGYuIjkk4WPfpNuhmM9Q3MegsVokqebg2WYnyvGCrx5xPBJPtPNwkkzdO1lPfb-FcVMSKfpXUC5VB7Opjf8yG4eW6ny5FeO4UXgtsbgcMV2A/s1600/aluminum+foundry+flask+design.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5727188893993996546" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXLzEzhCE2WIocLMGiDXl8KMjmMxlyuIUOmGYuIjkk4WPfpNuhmM9Q3MegsVokqebg2WYnyvGCrx5xPBJPtPNwkkzdO1lPfb-FcVMSKfpXUC5VB7Opjf8yG4eW6ny5FeO4UXgtsbgcMV2A/s200/aluminum+foundry+flask+design.jpg" style="cursor: hand; height: 78px; width: 122px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixGNGX-6jBpirak-btdMMkSl7ZhvJmUjS1eYceMlKycHsljBTPFpT0jQGn1U7o2LeBNlMrax04maehE2r5jXW1mztiLGuzqm1wDMWKDqWD6p7-czOU2S30t3Jn3NCgiDfZclCNSdPzOpka/s1600/aluminum+foundry+flask+copen+and+drag.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5727188886434508786" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixGNGX-6jBpirak-btdMMkSl7ZhvJmUjS1eYceMlKycHsljBTPFpT0jQGn1U7o2LeBNlMrax04maehE2r5jXW1mztiLGuzqm1wDMWKDqWD6p7-czOU2S30t3Jn3NCgiDfZclCNSdPzOpka/s200/aluminum+foundry+flask+copen+and+drag.jpg" style="cursor: hand; height: 77px; width: 134px;" /></a><br />
I made two patterns for each side of the flask, so the <a href="http://www.flamingfurnace.com/2011/02/sand-casting-terminology.html">drag </a>part is just a mirror image of the <a href="http://www.flamingfurnace.com/2011/02/sand-casting-terminology.html">cope</a>. The third pattern is my FlamingFurnace plaque name and flask size.<br />
I made it optional to make the sand mould impression with or without it.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiklhP2r9TIziwng4qu8fxHHNGaU-rYGdDfn8yHqMTCCa7NU6wW60MZdNAOQLfv9xSEiGXW67OSIK9YQ4nyrGystxXTfEL-0BfcmBIwri6stABTAAXrIRULwphw3QnR_jNlJ7i-ktmYxIie/s1600/foundry+flask+pattern.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5727183832035612242" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiklhP2r9TIziwng4qu8fxHHNGaU-rYGdDfn8yHqMTCCa7NU6wW60MZdNAOQLfv9xSEiGXW67OSIK9YQ4nyrGystxXTfEL-0BfcmBIwri6stABTAAXrIRULwphw3QnR_jNlJ7i-ktmYxIie/s200/foundry+flask+pattern.jpg" style="cursor: hand; height: 82px; width: 106px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhayjdkFzUlWhfnOjt81T5n8Xi-MtwHWmXLj3mPNeORdreZFxG7YzYRQh646Z3VQzOqNnPnrOrfICD3zxY3FJlLCehaH6DqYT_LD6JQjh6KLICs7XJHFlmJH4ygYDqSWj3f96JT8ORUGKOs/s1600/foundry+aluminum+ingots.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5727183698268654626" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhayjdkFzUlWhfnOjt81T5n8Xi-MtwHWmXLj3mPNeORdreZFxG7YzYRQh646Z3VQzOqNnPnrOrfICD3zxY3FJlLCehaH6DqYT_LD6JQjh6KLICs7XJHFlmJH4ygYDqSWj3f96JT8ORUGKOs/s200/foundry+aluminum+ingots.jpg" style="cursor: hand; height: 82px; width: 115px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4a2Hd1B50wa1VKDA5YZ4sAckTmauIEQ6zaSBskMnzKLQ8BEWNibHVe6hfpgpIJ2v3MBhBhUMLxogH6D6uAgX1MwR8mJr0d6C1LS4-rQQGEDlBtseYjQVQwDLBzOFP84Z8Lp9fwmkAwk-c/s1600/large+foundry+flask.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5727183833321894850" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4a2Hd1B50wa1VKDA5YZ4sAckTmauIEQ6zaSBskMnzKLQ8BEWNibHVe6hfpgpIJ2v3MBhBhUMLxogH6D6uAgX1MwR8mJr0d6C1LS4-rQQGEDlBtseYjQVQwDLBzOFP84Z8Lp9fwmkAwk-c/s200/large+foundry+flask.jpg" style="cursor: hand; height: 81px; width: 112px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikT2wv7f_DhTFU9IRgzkD0UMb8EZkCSrl8iOT61lBgK6RAtvSsq9jMFHKM0T6_W9PLEPi_Fx3EqrcTbH_HGLbjnv6swEwBXMUJBPtInYmDNUnBlRcKHpETo23i7GaYXOnr3Wqb8v4rfqlD/s1600/aluminum+foundry+casting+shake.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5727183686326371410" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikT2wv7f_DhTFU9IRgzkD0UMb8EZkCSrl8iOT61lBgK6RAtvSsq9jMFHKM0T6_W9PLEPi_Fx3EqrcTbH_HGLbjnv6swEwBXMUJBPtInYmDNUnBlRcKHpETo23i7GaYXOnr3Wqb8v4rfqlD/s200/aluminum+foundry+casting+shake.jpg" style="cursor: hand; height: 82px; width: 114px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4pznpgk6wvgaoNmEQ4jRUAoXY7osYZwuwPL_KRPsq7c3H2QbAsZYrcNev69fCNjRJiXApQy8FpIfdgpB5CGS9YHRY5hXd1llEtlxUxQZPijfOxqjbRaTYxr1RH4cN0VmXBcc6EGrBQ4PG/s1600/foundry+flask+casting.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5727183709009192738" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4pznpgk6wvgaoNmEQ4jRUAoXY7osYZwuwPL_KRPsq7c3H2QbAsZYrcNev69fCNjRJiXApQy8FpIfdgpB5CGS9YHRY5hXd1llEtlxUxQZPijfOxqjbRaTYxr1RH4cN0VmXBcc6EGrBQ4PG/s200/foundry+flask+casting.jpg" style="cursor: hand; height: 79px; width: 116px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-87KKEAdgGtYu7C2k0LDuNaKWR1u19U0MDSMXTlKq3iVbiXZP5nhMch7qW7cflkFFQXxoFkssancNGI8JUKiS6nL7XYjRNT7MTb-Zx7I-_Jti_yn-HsQqN1qwjJHhKqBmnjgYRptGCK3i/s1600/foundry+flask+one+side.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5727183819443793170" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-87KKEAdgGtYu7C2k0LDuNaKWR1u19U0MDSMXTlKq3iVbiXZP5nhMch7qW7cflkFFQXxoFkssancNGI8JUKiS6nL7XYjRNT7MTb-Zx7I-_Jti_yn-HsQqN1qwjJHhKqBmnjgYRptGCK3i/s200/foundry+flask+one+side.jpg" style="cursor: hand; height: 80px; width: 104px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLNmBo1IUoWfHEVt2tZLUV-MnhVewdCmeWj3lpuQLzVJgs10QT_ZZOE8dDVsDFCipKwzSSyoZo4SfHG-Rpf5N7qtoWSnS2tUOI0rGo7Kr57x787Q3D9HyDIiEfsN832CbvCT4tCfs-fnsZ/s1600/foundry+flask+back.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5727183702678130130" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLNmBo1IUoWfHEVt2tZLUV-MnhVewdCmeWj3lpuQLzVJgs10QT_ZZOE8dDVsDFCipKwzSSyoZo4SfHG-Rpf5N7qtoWSnS2tUOI0rGo7Kr57x787Q3D9HyDIiEfsN832CbvCT4tCfs-fnsZ/s200/foundry+flask+back.jpg" style="cursor: hand; height: 78px; width: 124px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh68AC0cYxwBAAN01N-a_Q5JtsmR22Tuk2yMWzqBgdlnH_X4N6Psvy-D-iuqepzPSThDUNdGixwwUQPCzXCpXma_lVx6I5U1NnPSTX4WokXspEYvYXVbnGOOW_H7Y71Xtb0okeJRvZDqCZo/s1600/aluminum+foundry+flask+casting+and+pattern.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5727183691203020626" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh68AC0cYxwBAAN01N-a_Q5JtsmR22Tuk2yMWzqBgdlnH_X4N6Psvy-D-iuqepzPSThDUNdGixwwUQPCzXCpXma_lVx6I5U1NnPSTX4WokXspEYvYXVbnGOOW_H7Y71Xtb0okeJRvZDqCZo/s200/aluminum+foundry+flask+casting+and+pattern.jpg" style="cursor: hand; height: 80px; width: 119px;" /></a><br />
<br />
<iframe frameborder="0" height="315" src="http://www.youtube.com/embed/PBq853uYW5A?rel=0" width="420"></iframe><br />
In the next image you can a correction I made to the gating system for the sprue, riser. This small change from the gating system I have in the video will prevent porosity.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoXCibfpLbcXG6S-tH3j16hISbUE1QULltE-euHzXRBTPL8a3LRtOvSt2Dd4PBf9fkPfE-BQMFxYAgJzhyX1IVpvDfDDo4uyB24DsR24y0s2pB65pjQCr2wVgbfSot4ZpaPKFcK9jpVzKa/s1600/aluminum+foundry+flask+casting+better++sprue+riser+gating+system.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5731262270665996114" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoXCibfpLbcXG6S-tH3j16hISbUE1QULltE-euHzXRBTPL8a3LRtOvSt2Dd4PBf9fkPfE-BQMFxYAgJzhyX1IVpvDfDDo4uyB24DsR24y0s2pB65pjQCr2wVgbfSot4ZpaPKFcK9jpVzKa/s200/aluminum+foundry+flask+casting+better++sprue+riser+gating+system.JPG" style="cursor: hand; height: 166px; width: 225px;" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-788615495037134972012-03-14T07:36:00.024-07:002013-01-04T11:50:32.978-08:00Green sand casting, New Jack Plane HandlesI got a vintage Stanley jack plane no5 a few years ago and the back handle was broken where the bolt supports it, I found it was uncomfortable to work with the plane. The front handle was a bit cracked but after my baby son decided to use it as a ball it took him exactly five minutes to crack it into two halves. I don't know what material these handles where made from but it looks some type of resin before the plastic age. I decided to duplicate the two handles and sand cast new handles using my <a href="http://www.flamingfurnace.com/p/foundry-terminology.html">aluminum foundry</a>. I also wanted a polished handles so it would be a unique jack plane. I checked on the internet and I did see aluminum handles that where manufacture for one of the hand planes at some stage. Making the <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">sand mould</a> was the easy part, creating the correct bolt core and angle for the back handle was a different story ;-)<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicDD7VXi6PACOn8jjtGa672w9HbPdb83Zxx6F7kPNw18molrPdB3mlQvRXNMyU1VFOHDritz1Oq62DK21fZcQRRwmKupxgfQk-mXbWedkBXTftMbJ9tK9-cfXpYAJcR9QOJtTyx_q0Tddv/s1600/aluminum+foundry%252C+jack+plane+handle+pattern.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5719766105225122930" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicDD7VXi6PACOn8jjtGa672w9HbPdb83Zxx6F7kPNw18molrPdB3mlQvRXNMyU1VFOHDritz1Oq62DK21fZcQRRwmKupxgfQk-mXbWedkBXTftMbJ9tK9-cfXpYAJcR9QOJtTyx_q0Tddv/s200/aluminum+foundry%252C+jack+plane+handle+pattern.jpg" style="cursor: hand; height: 80px; width: 133px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqHYAY-mgSnLkM1L-ndSLIWEBzpn4R9v4ILzKz-MD3gRo4xEvNDDF8d_j2lmuIcgrzdyVseBj-fNeyUcC-2989UL5F47t_l3TFNovcfmlsbL8BnG-ErqEDrSmJg5EVEt9ZQoRzgGoBKI8H/s1600/foundry+flask+sprue+and+riser+pattern+mould.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5719766099110252834" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqHYAY-mgSnLkM1L-ndSLIWEBzpn4R9v4ILzKz-MD3gRo4xEvNDDF8d_j2lmuIcgrzdyVseBj-fNeyUcC-2989UL5F47t_l3TFNovcfmlsbL8BnG-ErqEDrSmJg5EVEt9ZQoRzgGoBKI8H/s200/foundry+flask+sprue+and+riser+pattern+mould.jpg" style="cursor: hand; height: 81px; width: 123px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFSbuyseJzzgm0P9iI0Dd-I2l-vZHAlcNGV_6Grl7Tt_Ks0IF9A5ptb0ZAiFMAr4gUwF1G1Wcgt0tBGmVFOL3jgGbqde_aS8Fge6sMcWK4y-VJqxUYs-0u-xX8EirNP3iDbcDNPEQ3woAc/s1600/aluminum+foundry+casting+cooling+in+flask.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5719768411907624818" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFSbuyseJzzgm0P9iI0Dd-I2l-vZHAlcNGV_6Grl7Tt_Ks0IF9A5ptb0ZAiFMAr4gUwF1G1Wcgt0tBGmVFOL3jgGbqde_aS8Fge6sMcWK4y-VJqxUYs-0u-xX8EirNP3iDbcDNPEQ3woAc/s200/aluminum+foundry+casting+cooling+in+flask.jpg" style="cursor: hand; height: 86px; width: 117px;" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkj4_VIs0YlJowFOvlNAW0IEA4o8bP3iQeTikFmJUAlMBdaUMVMTgkpx9nxLkIFbmoE4GvezH3zxEPYB4UV2eqS4LP9mdRrCnvQvL9tvqotI-W8AqXTgx3wPq4ZlFfm4gN_o58RTvBxVdn/s1600/aluminum+foundry+flask++casting+sprue+and+riser.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5719768427224299778" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkj4_VIs0YlJowFOvlNAW0IEA4o8bP3iQeTikFmJUAlMBdaUMVMTgkpx9nxLkIFbmoE4GvezH3zxEPYB4UV2eqS4LP9mdRrCnvQvL9tvqotI-W8AqXTgx3wPq4ZlFfm4gN_o58RTvBxVdn/s200/aluminum+foundry+flask++casting+sprue+and+riser.jpg" style="cursor: hand; height: 83px; width: 115px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpHeGR1EQcq7UnJi8cRBk7MjpOZlUhFVstpIy1iMbToR38yNh_tFnmF1GQMp5VjBfBPPxMhUF40glijyHEQ0qVNB1SEdTw7kSrsKUVedyRM37GORQM2FTTE20rFx1D0ZQUJRCplwNoyvZM/s1600/aluminum+foundry+open+flask+casting+cooling.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5719768430564501298" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpHeGR1EQcq7UnJi8cRBk7MjpOZlUhFVstpIy1iMbToR38yNh_tFnmF1GQMp5VjBfBPPxMhUF40glijyHEQ0qVNB1SEdTw7kSrsKUVedyRM37GORQM2FTTE20rFx1D0ZQUJRCplwNoyvZM/s200/aluminum+foundry+open+flask+casting+cooling.jpg" style="cursor: hand; height: 83px; width: 114px;" /></a><br />
The first casting was perfect my plan was to drill the bolt hole after the casting. The front handle drilling was accurate but on the back handle I drilled the wrong angle for the bolt to fit correctly. I experimented with different core types I didn't want to make the traditional sand core. The second and third casting of the core failed but on the forth casting I decided to use a 9mm diameter metal tube, 1.5mm thick and 6mm inner core diameter. I heated the metal tube before placing it in the <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">flask</a> and pouring the molten aluminum. This casting was successful.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjghg5WkD9L7atd6UQ1Jb7uuCHHendLcY3etp0qlGzKWdb1FJCrGchtMj_WNgnCTk7cnSpfzm2kCF9S3MOVe4yy_Ov44kApSFCLgJRGb96LL9ludHi_-zbFUUPYIYrA_-vwnWcaUXHHjZrK/s1600/foundry+aluminum+handle+casting.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5719766120770884450" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjghg5WkD9L7atd6UQ1Jb7uuCHHendLcY3etp0qlGzKWdb1FJCrGchtMj_WNgnCTk7cnSpfzm2kCF9S3MOVe4yy_Ov44kApSFCLgJRGb96LL9ludHi_-zbFUUPYIYrA_-vwnWcaUXHHjZrK/s200/foundry+aluminum+handle+casting.jpg" style="cursor: hand; height: 82px; width: 111px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQl7QCg6sLekchoM9Dn87FnU5nvabGzDEd3joJqCQ0QnqB5-ADC4_ajzFBH7UN3CB1LjYDiZWyEIwD8wtRf9nXVB4Qxc7HrE7blgfgiVyFAqinzPGEsHEpyJfqNZoaDDIrIWgGO8XKfFId/s1600/aluminum+foundry+casting+handles+with+sprue+and+riser.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5720069220081442866" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQl7QCg6sLekchoM9Dn87FnU5nvabGzDEd3joJqCQ0QnqB5-ADC4_ajzFBH7UN3CB1LjYDiZWyEIwD8wtRf9nXVB4Qxc7HrE7blgfgiVyFAqinzPGEsHEpyJfqNZoaDDIrIWgGO8XKfFId/s200/aluminum+foundry+casting+handles+with+sprue+and+riser.jpg" style="cursor: hand; height: 83px; width: 110px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKPF3rv4nxIY7NGAH5x3tTvYc-CPOWm5-hrijCxXwX5-N8CD3LJh6g12-TXcCmt_kzGy4ANbY9aUuevX9DqGktwEpraqoWbNz_pHJOwGe1WQcbKo7K9K6Ybeu1Kj57MaEM1khV4hm4VAE8/s1600/foundry+flask%252C+cope+and+drag%252C+handle+pattern.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5719766094272561330" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKPF3rv4nxIY7NGAH5x3tTvYc-CPOWm5-hrijCxXwX5-N8CD3LJh6g12-TXcCmt_kzGy4ANbY9aUuevX9DqGktwEpraqoWbNz_pHJOwGe1WQcbKo7K9K6Ybeu1Kj57MaEM1khV4hm4VAE8/s200/foundry+flask%252C+cope+and+drag%252C+handle+pattern.jpg" style="cursor: hand; height: 84px; width: 112px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdVy_uHHQa3vWX84QkpWFQqXnCzvOTjba4Arzxm2eM1F4g4lmkPrJMMS-2sRyilCfQ0RBWJwtICUBnEaIeOOM8RUt2Kz1EONqOWbm4fzK423iYrgFM_KjLoPmguhUMrwEHjZ-BUQIzvUWS/s1600/aluminum+foundry+pattern+impersion+in+sand+mould.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5719766112088993394" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdVy_uHHQa3vWX84QkpWFQqXnCzvOTjba4Arzxm2eM1F4g4lmkPrJMMS-2sRyilCfQ0RBWJwtICUBnEaIeOOM8RUt2Kz1EONqOWbm4fzK423iYrgFM_KjLoPmguhUMrwEHjZ-BUQIzvUWS/s200/aluminum+foundry+pattern+impersion+in+sand+mould.jpg" style="cursor: hand; height: 85px; width: 109px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwKNZFSBcbbNCp9L6Q9suB0iT8ZrFcLqURV2VytRUQfkK1pVIko6pGtxO8iAahz9Bv9mWQialywSWXwJg_cnXtgc5QlKqFIFTaKe7mdO48VLo-U92YFaW6Kg59bYde6UHh5HtGtWAOM7ox/s1600/aluminum+foundry+flask+shake+out.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5719768409082968018" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwKNZFSBcbbNCp9L6Q9suB0iT8ZrFcLqURV2VytRUQfkK1pVIko6pGtxO8iAahz9Bv9mWQialywSWXwJg_cnXtgc5QlKqFIFTaKe7mdO48VLo-U92YFaW6Kg59bYde6UHh5HtGtWAOM7ox/s200/aluminum+foundry+flask+shake+out.jpg" style="cursor: hand; height: 84px; width: 115px;" /></a><br />
Before I made the <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">sand mould </a>I reconstructed the broken end of the back handle. I used a filler and varnish to prevent the sand sticking to the <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">pattern</a>. I also used my foundry casting <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">green sand</a> and it proved again to be very suitable for this type of castings. I left a wide <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">gating system </a>and<a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html"> sprue/riser </a>well and that prevented any casting defects. After the casting was ready I cut off the sprue and riser and drilled the bolt holes.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkaJlJM1HNJLeSOnsF4yL87HbcBuNj9ziTWZC0FxLnehqEBKkylpYZHeY0d7qFUojnhOidORfTEJsSy1ZPH-PxBIZSZMRjo05MNh5g3JD6tfpdI7qZk6xyWMZHdwtGKWTBtaeHG1WWSjSq/s1600/aluminum++foundry+handles+sprue+and+riser+cut.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5720069203825245170" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkaJlJM1HNJLeSOnsF4yL87HbcBuNj9ziTWZC0FxLnehqEBKkylpYZHeY0d7qFUojnhOidORfTEJsSy1ZPH-PxBIZSZMRjo05MNh5g3JD6tfpdI7qZk6xyWMZHdwtGKWTBtaeHG1WWSjSq/s200/aluminum++foundry+handles+sprue+and+riser+cut.jpg" style="cursor: hand; height: 81px; width: 109px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFci407aiQLjkP40-lqgPPfWoumWg1t8asJTAriY00pQDW8NEOd4r3tA6xdlvFB66ctsRfhXLZxVUKRRwvZn4AolYXfM6DRAh04Yi3L0g9Fl0nbAfQQbfhXWOnDtOTAh3-DqVbJQCtPObN/s1600/aluminum+foundry+sprue+riser+in+green+sand.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5719768404245049538" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFci407aiQLjkP40-lqgPPfWoumWg1t8asJTAriY00pQDW8NEOd4r3tA6xdlvFB66ctsRfhXLZxVUKRRwvZn4AolYXfM6DRAh04Yi3L0g9Fl0nbAfQQbfhXWOnDtOTAh3-DqVbJQCtPObN/s200/aluminum+foundry+sprue+riser+in+green+sand.jpg" style="cursor: hand; height: 80px; width: 107px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiF9DCVzKWr-ptXsJnPDASy_tDV-1kW63uOQI0VCq52CWKoE3afM0ogLUOjHkGZvHO_C1YH8y7V8e9ZW8hgaKsXaWCEisAaITZqNbV9dBfUHleva0Uk6hoQdkpDGT9Ipb2I8mShR1s5Q9yS/s1600/aluminum+foundry+casting+metal+core+with+sprue+and+riser.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5720069212275926306" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiF9DCVzKWr-ptXsJnPDASy_tDV-1kW63uOQI0VCq52CWKoE3afM0ogLUOjHkGZvHO_C1YH8y7V8e9ZW8hgaKsXaWCEisAaITZqNbV9dBfUHleva0Uk6hoQdkpDGT9Ipb2I8mShR1s5Q9yS/s200/aluminum+foundry+casting+metal+core+with+sprue+and+riser.jpg" style="cursor: hand; height: 82px; width: 99px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdfFjvjGHh45J-96UACL_t071UYt3jnru5zkBVeUSHsSGCyCGnVFGvTo4wxCKhjH18EpwngpkjIwHI1BwSSwff2JPLu4R780jVg_tVPZ52Bst_QssE7n5fXy3jWGiqOePf4RqZZgizPVQR/s1600/aluminum+foundry+drilling+back+handle+core.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5720069215243585170" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdfFjvjGHh45J-96UACL_t071UYt3jnru5zkBVeUSHsSGCyCGnVFGvTo4wxCKhjH18EpwngpkjIwHI1BwSSwff2JPLu4R780jVg_tVPZ52Bst_QssE7n5fXy3jWGiqOePf4RqZZgizPVQR/s200/aluminum+foundry+drilling+back+handle+core.jpg" style="cursor: hand; height: 82px; width: 117px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyqFSbsT0YtqNkLIfS-H_1IcDWkOlgg70LA-z7I4MmbXlEEksnIqmtbNrjfiWAiFb5BZqrNIs6UBy-r_EZuv8zqzj5JyyEvyvzM28YvYqnL_2AEQbqZs-OhUvMYGZpIElu2_zPtnqmAZt-/s1600/aluminum+casting+drilling+front+aluminum+handle.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5720069208574533586" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyqFSbsT0YtqNkLIfS-H_1IcDWkOlgg70LA-z7I4MmbXlEEksnIqmtbNrjfiWAiFb5BZqrNIs6UBy-r_EZuv8zqzj5JyyEvyvzM28YvYqnL_2AEQbqZs-OhUvMYGZpIElu2_zPtnqmAZt-/s200/aluminum+casting+drilling+front+aluminum+handle.jpg" style="cursor: hand; height: 80px; width: 121px;" /></a><br />
In the next set of images you can see the unsuccessful handle castings back in the <a href="http://www.flamingfurnace.com/p/foundry-terminology.html">crucible </a>for another remelting session. After the bolt holes where done I used my buffing wheel and polished the new aluminum handles.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigdd3erqtM6Q0Z_3-edfE14IQ6xpfnjzNClJCNcZRq11Vmt0D_-vxJE4PV8IS8Uq_pficVJUduduumA9RTOKnd1235KdVx_u9NshwRtUDM8-LKVT1rx5XFSN_aFU7UKqLuYspZdu9JfVWk/s1600/aluminum+foundry+crucible.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5720073130740085074" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigdd3erqtM6Q0Z_3-edfE14IQ6xpfnjzNClJCNcZRq11Vmt0D_-vxJE4PV8IS8Uq_pficVJUduduumA9RTOKnd1235KdVx_u9NshwRtUDM8-LKVT1rx5XFSN_aFU7UKqLuYspZdu9JfVWk/s200/aluminum+foundry+crucible.jpg" style="cursor: hand; height: 83px; width: 120px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcL4pGn_oGJgk5qkZF38k2D7j1SIA-ZaNmYUnLlcb6UCQ-we-xLsY09-InE8892v-Dh_HnNxIEX3XKKOlSfP4gh9FMIw-gEcib7uzIbx09tpuASYYR92DkDQ1It8-LlHtSKtQiNMvV6Pkl/s1600/aluminum+foundry+casting+with+core.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5720073132284007842" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcL4pGn_oGJgk5qkZF38k2D7j1SIA-ZaNmYUnLlcb6UCQ-we-xLsY09-InE8892v-Dh_HnNxIEX3XKKOlSfP4gh9FMIw-gEcib7uzIbx09tpuASYYR92DkDQ1It8-LlHtSKtQiNMvV6Pkl/s200/aluminum+foundry+casting+with+core.jpg" style="cursor: hand; height: 81px; width: 109px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEA-4JycmCWvkeP2Ee1ULDAr87dXjPU9sjUHJ3Q8mkduaKlgFEXBylkl4HRk2Dq6gfL-mmVV9OpP6iUMh15ZKUAaO4lIHHvHZ41KxGNY-86f6TOLyghBleN0fqAnDiCVjs6V6xy-AYhdEK/s1600/aluminum+foundy+polished+aluminum+handle+casting.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5720073146534257186" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEA-4JycmCWvkeP2Ee1ULDAr87dXjPU9sjUHJ3Q8mkduaKlgFEXBylkl4HRk2Dq6gfL-mmVV9OpP6iUMh15ZKUAaO4lIHHvHZ41KxGNY-86f6TOLyghBleN0fqAnDiCVjs6V6xy-AYhdEK/s200/aluminum+foundy+polished+aluminum+handle+casting.jpg" style="cursor: hand; height: 80px; width: 121px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglLU1ONhGBQwQWkzXjWGyK7SIjWnt4HNrqeaG1EV_436pZJ7hj6jh2cX9JzX8pdeDqr7BBbefWVeASL9TPHW7ycl9SxBVcY_0tifZnHTyKhbEu2blBM5j0EYkU2Vv7wMtfqx41BhDbOs1J/s1600/aluminum+foundry+polished+aluminum+handles.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5720073144162079122" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglLU1ONhGBQwQWkzXjWGyK7SIjWnt4HNrqeaG1EV_436pZJ7hj6jh2cX9JzX8pdeDqr7BBbefWVeASL9TPHW7ycl9SxBVcY_0tifZnHTyKhbEu2blBM5j0EYkU2Vv7wMtfqx41BhDbOs1J/s200/aluminum+foundry+polished+aluminum+handles.jpg" style="cursor: hand; height: 79px; width: 124px;" /></a><br />
In the next images you can see the jack plane with the new front and back aluminum handles ready for use.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKl_zLCnugPBkoORF1chFQpnBRpBNrS1G3QN_DOlKTV2X-Q18w26iNk0SysrNVn92ubgaUOrrnLfKs1CwBeyuLjaOZLASP-ppAR-CAnUATZDQh4nXUyhgpD_z4H3LP1FqBqLVP5RQtRDRJ/s1600/foundry+casting+aluminum+handle+and+broken+pattern.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5720073155901881762" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKl_zLCnugPBkoORF1chFQpnBRpBNrS1G3QN_DOlKTV2X-Q18w26iNk0SysrNVn92ubgaUOrrnLfKs1CwBeyuLjaOZLASP-ppAR-CAnUATZDQh4nXUyhgpD_z4H3LP1FqBqLVP5RQtRDRJ/s200/foundry+casting+aluminum+handle+and+broken+pattern.jpg" style="cursor: hand; height: 87px; width: 121px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivVDaJiGg7NO9crO4DlIm3juuWKRYoetlwpiIHelnnkeMH_p3uDDtv6kIxxhXskfLO4e9RQ5U6pUXxXRnfi1lUosLDso4qMwxu6kO4v7Saaenk7FepNfbvv3gajoqgOtP7wU2CiEPFBhP9/s1600/aluminum+foundry+casting++plane+handles.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5720074888354186514" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivVDaJiGg7NO9crO4DlIm3juuWKRYoetlwpiIHelnnkeMH_p3uDDtv6kIxxhXskfLO4e9RQ5U6pUXxXRnfi1lUosLDso4qMwxu6kO4v7Saaenk7FepNfbvv3gajoqgOtP7wU2CiEPFBhP9/s200/aluminum+foundry+casting++plane+handles.jpg" style="cursor: hand; height: 86px; width: 130px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8xXGRCS1phCJlZ2OMkJOZm7T4EPE8ZU1IIfYmZ0VJG1B3ZKsttZmipIXBF9MytL241nXo-t5IUhoHtKQ27DQ7ISQ4IOJuV9rGjVbjV0u37UARFlFkXDLLGlNeCsDAfJ10_0f4SbX5qJpN/s1600/aluminum+foundry++casting%252C+handles+in+place.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5720074886582593522" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8xXGRCS1phCJlZ2OMkJOZm7T4EPE8ZU1IIfYmZ0VJG1B3ZKsttZmipIXBF9MytL241nXo-t5IUhoHtKQ27DQ7ISQ4IOJuV9rGjVbjV0u37UARFlFkXDLLGlNeCsDAfJ10_0f4SbX5qJpN/s200/aluminum+foundry++casting%252C+handles+in+place.jpg" style="cursor: hand; height: 85px; width: 125px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5XqPnNXt-nond6uMR3q1E5JhLNCTSGve3Yz-NZNaqu1o91TSSIAH-dDFtUAPYFPq5XSCG4oHLdGeAz8umN5B_65yZkU-GJRCw4QDXCHMb37PS7y3yiCnU1X0lzUY5B1thVCOKuv1iZ6fU/s1600/aluminum+foundry+casting+broken+pattern.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5720074894615641410" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5XqPnNXt-nond6uMR3q1E5JhLNCTSGve3Yz-NZNaqu1o91TSSIAH-dDFtUAPYFPq5XSCG4oHLdGeAz8umN5B_65yZkU-GJRCw4QDXCHMb37PS7y3yiCnU1X0lzUY5B1thVCOKuv1iZ6fU/s200/aluminum+foundry+casting+broken+pattern.jpg" style="cursor: hand; height: 85px; width: 125px;" /></a><br />
<u><span style="color: red;"><strong>27/03/2012</strong></span></u><br />
Today I was making a new pattern using my jack plane with the new aluminum handles first time. works great ;-)<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6uRGDfrQYj7WijouT7d9lCrMyu4QB9N5TedyuR2CuAD99xtLCu5FuBx2WSMU7v6GW_2T80fWkf_kk_GVMl5FcveY9cLFgOiuvpLgH5y1ML3VCEdmFmzMAw1wXaDsxjoZjyH1Kd2QyFdIB/s1600/aluminum+handles+first+use.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5724516980429745314" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6uRGDfrQYj7WijouT7d9lCrMyu4QB9N5TedyuR2CuAD99xtLCu5FuBx2WSMU7v6GW_2T80fWkf_kk_GVMl5FcveY9cLFgOiuvpLgH5y1ML3VCEdmFmzMAw1wXaDsxjoZjyH1Kd2QyFdIB/s200/aluminum+handles+first+use.jpg" style="cursor: hand; height: 80px; width: 123px;" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-45165748820726568462012-02-29T09:48:00.023-08:002012-02-29T13:48:40.124-08:00Aluminum Foundry Sand Casting House no. 25, 38After my last few successfully castings using greensand I decided to make two new aluminum numbers for my house and for my parents in law. After casting the <a href="http://www.flamingfurnace.com/2012/02/aluminum-diving-plaque-foundry-sand.html">"diving plaque"</a> I had more experience with this type of pattern. For the first pattern with the no. 38 I used 9mm MDF for the plaque base and my old metal numbers. I used plastic rope to create the plaque boarder.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ_nqZL77irRkAzgYCGXHFtN3Y00nK_frpGOSdtR5Rxh36ql3TuZhcG5RUFs0sKTHLGFjkLQsTROBdGMZQlfsNyjRkGQWgkI_BI-RuicF4b6n8pstYMZZKLALLikwVRQpbXIbWdyQViwZa/s1600/foundry+green+sand+casting+3+.jpg"><img style="WIDTH: 125px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714618584045014642" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ_nqZL77irRkAzgYCGXHFtN3Y00nK_frpGOSdtR5Rxh36ql3TuZhcG5RUFs0sKTHLGFjkLQsTROBdGMZQlfsNyjRkGQWgkI_BI-RuicF4b6n8pstYMZZKLALLikwVRQpbXIbWdyQViwZa/s200/foundry+green+sand+casting+3+.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHjV5gAGivQKIib0kGw0rzAvgDwlSuvYr4op6ZVJ7nX9nG6r80hBFsZ2WbMh-yuWmv1TAPWBrvEqj1VGKIfS6GbJg7xBJtuQl5ne1OaYhX95hAtqvzCZNuMmDHYlYxWplzg0U9P2Dz9_u8/s1600/aluminum+house+no+plaque.JPG"><img style="WIDTH: 130px; HEIGHT: 91px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714618591940126898" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHjV5gAGivQKIib0kGw0rzAvgDwlSuvYr4op6ZVJ7nX9nG6r80hBFsZ2WbMh-yuWmv1TAPWBrvEqj1VGKIfS6GbJg7xBJtuQl5ne1OaYhX95hAtqvzCZNuMmDHYlYxWplzg0U9P2Dz9_u8/s200/aluminum+house+no+plaque.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGB1L3NCRCIlVD9wUAXkyapLYWtABVpvABBTXJbm9YthQXsu5a33CSy01GeJzpY1NUaenOkDpJimEh9nQrffMa5Iwo-vjXndc1y8cZTCCfBaxOdCgzxTcsko4qT7a8k0X60wszXx_X7mUv/s1600/foundry+green+sand+casting+4+.jpg"><img style="WIDTH: 120px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714621598243291794" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGB1L3NCRCIlVD9wUAXkyapLYWtABVpvABBTXJbm9YthQXsu5a33CSy01GeJzpY1NUaenOkDpJimEh9nQrffMa5Iwo-vjXndc1y8cZTCCfBaxOdCgzxTcsko4qT7a8k0X60wszXx_X7mUv/s200/foundry+green+sand+casting+4+.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCsi96i1z0a2dEgC_5lUNJYBPWX7Tr9KV8U6nni6RNXTBad0MoCiXkv4hh6xcyT8RHn7QooyXbLJc9cr4Bny6L0z4bPn5fqHYYzGmwU_zCjzvhFlAy1l6U0N7qbyXV9ECepDSTtvhJ_JEa/s1600/foundry+flask+ready+for+aluminum+pour+.jpg"><img style="WIDTH: 124px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714621585307197938" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCsi96i1z0a2dEgC_5lUNJYBPWX7Tr9KV8U6nni6RNXTBad0MoCiXkv4hh6xcyT8RHn7QooyXbLJc9cr4Bny6L0z4bPn5fqHYYzGmwU_zCjzvhFlAy1l6U0N7qbyXV9ECepDSTtvhJ_JEa/s200/foundry+flask+ready+for+aluminum+pour+.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfK-CpLd07debC57y6-T2aEkCyuITl2Ww22Pp2dmQavYeC4Owk-dKNZFnDZMVTci75Er70mSXZMgP64eSu2htFsywC1kFtpHP8CFKuS40VRE9E7YnD-uStDT_CNfK6GosZ5LxTQFUudOd1/s1600/foundry+molten+aluminum+in+crucible+.jpg"><img style="WIDTH: 122px; HEIGHT: 83px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714624073740520866" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfK-CpLd07debC57y6-T2aEkCyuITl2Ww22Pp2dmQavYeC4Owk-dKNZFnDZMVTci75Er70mSXZMgP64eSu2htFsywC1kFtpHP8CFKuS40VRE9E7YnD-uStDT_CNfK6GosZ5LxTQFUudOd1/s200/foundry+molten+aluminum+in+crucible+.jpg" /></a><br />The main thing with plaques is to create a good draft (angle) around the letters using some sort of filler that will be easy to sand and smooth that way the letters impression in the sand mould will come out in good quality without breaking the sand. Its important to get the sand mould correct the first time because plaques are all about good finishing, any casting defects are hard to fix and will be visible to the observer eye and definatly to a metal caster.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEwWzY59c0LkAi0NBFrnqzkUWIMu_MLDdF0sLbLwY0677rD00K6Mt72jeEHXKqUCNp5QNALAQiZYti9-bVn3bgNCaN3BWrLJgNe82E8VOOfn2KqfsEv6bwi6K-pBAr_MvfOKBUSin1e9qH/s1600/foundry+green+sand+casting+5+.jpg"><img style="WIDTH: 128px; HEIGHT: 89px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714625029735732626" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEwWzY59c0LkAi0NBFrnqzkUWIMu_MLDdF0sLbLwY0677rD00K6Mt72jeEHXKqUCNp5QNALAQiZYti9-bVn3bgNCaN3BWrLJgNe82E8VOOfn2KqfsEv6bwi6K-pBAr_MvfOKBUSin1e9qH/s200/foundry+green+sand+casting+5+.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmqhvHabxMcsfeacseH8JBb8rYr0XOYZ39SG25D7M2EMpdAJzit04T0I9kOhJCLKJH2_38sl71qIZPUyYhbhSShC8j5Gizu-8-QiYkCD2Wk374f_zn_FeDujqozalQ8wf4Qb8mqq9xVICi/s1600/foundry+green+sand+casting+6+.jpg"><img style="WIDTH: 129px; HEIGHT: 90px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714625030401556642" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmqhvHabxMcsfeacseH8JBb8rYr0XOYZ39SG25D7M2EMpdAJzit04T0I9kOhJCLKJH2_38sl71qIZPUyYhbhSShC8j5Gizu-8-QiYkCD2Wk374f_zn_FeDujqozalQ8wf4Qb8mqq9xVICi/s200/foundry+green+sand+casting+6+.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgS8xLh1V09qZ7gSf8oDbx-06m58kFF7r6iKPTXYs7uI-rq5NdPjuwZby9rl8QfatnfU0hXw-3vF1L_5QuwAwWF4C-5GcjbBz685tuDxrCE6O4YeAiDx6eW5mfnxEo5UzMFPfr0rtVfDj5b/s1600/foundry+green+sand+casting+7+.jpg"><img style="WIDTH: 123px; HEIGHT: 89px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714621589446930610" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgS8xLh1V09qZ7gSf8oDbx-06m58kFF7r6iKPTXYs7uI-rq5NdPjuwZby9rl8QfatnfU0hXw-3vF1L_5QuwAwWF4C-5GcjbBz685tuDxrCE6O4YeAiDx6eW5mfnxEo5UzMFPfr0rtVfDj5b/s200/foundry+green+sand+casting+7+.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAAJ1qtbSnuxpRonL9REGSyG5H7LvGC8I8QgWszXoILtreIB8D4Tq2DH3pXxTkDZ-BdYzY28b2rOYwl5YtLQrXG_hc27nOLb5XCen5t8LA82aZ3N6tn5fKqaQS3sd3j_sdIqg_tghAD8Kd/s1600/foundry+casting+38+.jpg"><img style="WIDTH: 124px; HEIGHT: 88px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714621579731658514" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAAJ1qtbSnuxpRonL9REGSyG5H7LvGC8I8QgWszXoILtreIB8D4Tq2DH3pXxTkDZ-BdYzY28b2rOYwl5YtLQrXG_hc27nOLb5XCen5t8LA82aZ3N6tn5fKqaQS3sd3j_sdIqg_tghAD8Kd/s200/foundry+casting+38+.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMExAssHVZwBEr9xmTSfjuNd3uiCfwqEJLi-R6T-TIzTzy0V-rcFIK9oVxyflPvuvPUvkGrGm4qaUeTr0lJk7LIWF2HbscvFvzdg37cBv0Cgv8sQAPfewtLNDDYdnhz8ENr4RFwrYo2Abb/s1600/foundry+casting+cut+sprue+and+riser+.jpg"><img style="WIDTH: 116px; HEIGHT: 88px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714621602699448194" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMExAssHVZwBEr9xmTSfjuNd3uiCfwqEJLi-R6T-TIzTzy0V-rcFIK9oVxyflPvuvPUvkGrGm4qaUeTr0lJk7LIWF2HbscvFvzdg37cBv0Cgv8sQAPfewtLNDDYdnhz8ENr4RFwrYo2Abb/s200/foundry+casting+cut+sprue+and+riser+.jpg" /></a><br />Using my new greensand I made the mould for the no. 38. The casting turned out well I just had a bit of grinding of aluminum flash around the plaque. I got carried away with the parting powder so that ruined a bit the flat surface around the number...... but that will be painted anyway ;-).<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizKDYpg2HiqKd4k9AhGF7tuL-uhAFv-5Im5umuWNbO2thzS6Sz9GIpGeCva5l93gNQs2kr17E0ys6xW8wMe9VQTqPixipch7o8tzWO6c2ZN92To0alQ-O0O2i-E82EEJ0OhRCOjk-7p_3I/s1600/foundry+casting+38+with+sprue+and+reiser+.jpg"><img style="WIDTH: 116px; HEIGHT: 84px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714624059647895106" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizKDYpg2HiqKd4k9AhGF7tuL-uhAFv-5Im5umuWNbO2thzS6Sz9GIpGeCva5l93gNQs2kr17E0ys6xW8wMe9VQTqPixipch7o8tzWO6c2ZN92To0alQ-O0O2i-E82EEJ0OhRCOjk-7p_3I/s200/foundry+casting+38+with+sprue+and+reiser+.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgF9GVMCNBVaD0gPUULkG9zmXoieCX8AzzzL9f2c_EywWShY-OP-qskwCotX3e3CTNbWX_KYKfred_kGYq2N9X2-CIcjhowp-Za2WcZHRYIn451LGhnt-9Y8Ru_nZJjohuaResYl-ghFahO/s1600/painting+aluminum+casting+.jpg"><img style="WIDTH: 118px; HEIGHT: 83px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714624065036733922" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgF9GVMCNBVaD0gPUULkG9zmXoieCX8AzzzL9f2c_EywWShY-OP-qskwCotX3e3CTNbWX_KYKfred_kGYq2N9X2-CIcjhowp-Za2WcZHRYIn451LGhnt-9Y8Ru_nZJjohuaResYl-ghFahO/s200/painting+aluminum+casting+.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjug1qnD7P5YP61udN9RvnLZ98euRZi32caN9uQMMWeZSBAofHgvSn32fPzPIKMx1EBS56GUU8QlXhpOYoucYUeSR69m4BRieA9f2MHF45pT57sBMbl34UETAtyeECNQagHwLuPGjnm0Ss1/s1600/aluminum+plaque+house+no+38+.jpg"><img style="WIDTH: 117px; HEIGHT: 83px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714624069312566738" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjug1qnD7P5YP61udN9RvnLZ98euRZi32caN9uQMMWeZSBAofHgvSn32fPzPIKMx1EBS56GUU8QlXhpOYoucYUeSR69m4BRieA9f2MHF45pT57sBMbl34UETAtyeECNQagHwLuPGjnm0Ss1/s200/aluminum+plaque+house+no+38+.jpg" /></a> <br />The second house number 25 was custom made from a-z, the base I made from MDF and also the letters. I used 8mm MDF to make the numbers so the numbers where chunky and needed a good draft around them. The last thing and VERY IMPORTANT, I used clear varnish for both plaques that prevents the sand from sticking to the pattern.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhE8R2GJWy9MuPm-j1L-HTTuEJODsZB76Uv8j58n1uI5g-r0pOAz3T5smJuu-5cZRlz6itAFLNH8ncrptDaIj-PS-mHrZkhiSuauFGFgBZ-TTjl-oo6mhXEPfX4e7kB19XkA_Vz4tCRnhij/s1600/foundry+aluminum+casting+2+.jpg"><img style="WIDTH: 126px; HEIGHT: 84px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714668440960964242" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhE8R2GJWy9MuPm-j1L-HTTuEJODsZB76Uv8j58n1uI5g-r0pOAz3T5smJuu-5cZRlz6itAFLNH8ncrptDaIj-PS-mHrZkhiSuauFGFgBZ-TTjl-oo6mhXEPfX4e7kB19XkA_Vz4tCRnhij/s200/foundry+aluminum+casting+2+.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpjTotugb_njJDKCV2cK11Ymj0E-fTwlI7ssM4ye-hRFcz3dQk1cMh5AAdig-NINMJFcG6PZtIWCfz9YJjjEgfINCuLVp8Q-bWFUcAtMkatKsI5e_q6AMrjvjlTkyFm98iFNoGONtHqMpZ/s1600/foundry+aluminum+casting+1+.jpg"><img style="WIDTH: 122px; HEIGHT: 86px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714668445834359538" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpjTotugb_njJDKCV2cK11Ymj0E-fTwlI7ssM4ye-hRFcz3dQk1cMh5AAdig-NINMJFcG6PZtIWCfz9YJjjEgfINCuLVp8Q-bWFUcAtMkatKsI5e_q6AMrjvjlTkyFm98iFNoGONtHqMpZ/s200/foundry+aluminum+casting+1+.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRDpI6bsylvKY1jJU7_4pLRyJoUbL3WGeC6pBOkVWLPPVVJFAEIzeu-t_WZzcn4rUEnrO1Vf_k34AffFFgjTBmaOtF4oxa_JyINQPL-4WpjRU1OrSdeCr5ztwEnYGYdr1VxTrk0SS0gI5g/s1600/foundry++aluminum+casting+3+.jpg"><img style="WIDTH: 116px; HEIGHT: 88px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714668456167398338" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRDpI6bsylvKY1jJU7_4pLRyJoUbL3WGeC6pBOkVWLPPVVJFAEIzeu-t_WZzcn4rUEnrO1Vf_k34AffFFgjTBmaOtF4oxa_JyINQPL-4WpjRU1OrSdeCr5ztwEnYGYdr1VxTrk0SS0gI5g/s200/foundry++aluminum+casting+3+.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgg4t-RBOIlACNtR4_C1mvFZDCfaAMpkam5d2zz0b2UKIFRwVyUqtaV-8rLM8zbQPljOf6v3vGwzrqHZK6Y0wg0uP1WO0IHLwuEVdc9ug3q6tGJVpGGM-uL2-kXmPdl8FfpCQuIoAknyOe5/s1600/foundry+aluminum+polish+.jpg"><img style="WIDTH: 118px; HEIGHT: 88px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714668457348929810" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgg4t-RBOIlACNtR4_C1mvFZDCfaAMpkam5d2zz0b2UKIFRwVyUqtaV-8rLM8zbQPljOf6v3vGwzrqHZK6Y0wg0uP1WO0IHLwuEVdc9ug3q6tGJVpGGM-uL2-kXmPdl8FfpCQuIoAknyOe5/s200/foundry+aluminum+polish+.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkQRL_v1iPQIA7WRuFWXUmkvvkCu8dqskoSPbpxLDBkg7A8I_CyU5EKsjlZZxB2bEwI9K1sASaUXZP22e1mvo-3yov6bch6mG6FEchzHjHYKpfw7PDRAYaKnW3wHmGKj21yKjco0ij9_jy/s1600/aluminum+plaque+no+paint+.jpg"><img style="WIDTH: 135px; HEIGHT: 89px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714668464284310530" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkQRL_v1iPQIA7WRuFWXUmkvvkCu8dqskoSPbpxLDBkg7A8I_CyU5EKsjlZZxB2bEwI9K1sASaUXZP22e1mvo-3yov6bch6mG6FEchzHjHYKpfw7PDRAYaKnW3wHmGKj21yKjco0ij9_jy/s200/aluminum+plaque+no+paint+.jpg" /></a><br />I almost thought the number 25 would have casting defects because I didn't have enough molten metal too fill the feeder on one side. To my surprise it was perfect. After cutting of the the sprue and riser and a bit of flash grinding I only had to give the numbers a good polish on the buffing wheel.<br />Last thing I drilled holes to mount it on the wall.<br />I used black gloss external metal paint for both of the number plaques and I polished the no. 25.<br />Both of them will be mounted on the wall of our houses for many years to come.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiI5dOxBjwSSHxBDoXu3d04dLq4S4gBAGQtNNfCcNtgX2sS3lz_OliQJyB9_RPFJd90k3Wj5E6vIFm4zbq5ZyszidpV0s6tAMMR8_YjC6vQRsQ7wvJik4Y6vT7gWoh-B4ypBXm0MZtyr-1W/s1600/aluminum+plaque+25+on+wall+.jpg"><img style="WIDTH: 148px; HEIGHT: 111px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714669552093046258" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiI5dOxBjwSSHxBDoXu3d04dLq4S4gBAGQtNNfCcNtgX2sS3lz_OliQJyB9_RPFJd90k3Wj5E6vIFm4zbq5ZyszidpV0s6tAMMR8_YjC6vQRsQ7wvJik4Y6vT7gWoh-B4ypBXm0MZtyr-1W/s200/aluminum+plaque+25+on+wall+.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirYoPEdAVbYbT-BGvYu78tjES7pCGnP1rGhw6cQYEdSXvH408Jqt6Q6ilIgkMy8OGm4Qj4Tj6zuqvkweoiZSE60BGe5l4oUqDq9ZbQ2VC9GZkh0LdUAKBUaHWINMFmlzU_MiJP5tfwjh3L/s1600/aluminum+plaque+38+on+wall+.jpg"><img style="WIDTH: 137px; HEIGHT: 109px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714625036757678466" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirYoPEdAVbYbT-BGvYu78tjES7pCGnP1rGhw6cQYEdSXvH408Jqt6Q6ilIgkMy8OGm4Qj4Tj6zuqvkweoiZSE60BGe5l4oUqDq9ZbQ2VC9GZkh0LdUAKBUaHWINMFmlzU_MiJP5tfwjh3L/s200/aluminum+plaque+38+on+wall+.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjU_jil0BHBQTRFJMagdWJfI37bduiePXDXCGeTAnHARjIIv7J0Kz5Y7ogceDEaucuseKnrhn7CH7zHmgyynGIX8cB7xw4f_W25JVp8X75cHPgPm67fg_AqwG4I4gTf8fhXjqPv-ogbwE5i/s1600/aluminum++casting+and+pattern+25%252C+38.jpg"><img style="WIDTH: 169px; HEIGHT: 110px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714669543542434866" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjU_jil0BHBQTRFJMagdWJfI37bduiePXDXCGeTAnHARjIIv7J0Kz5Y7ogceDEaucuseKnrhn7CH7zHmgyynGIX8cB7xw4f_W25JVp8X75cHPgPm67fg_AqwG4I4gTf8fhXjqPv-ogbwE5i/s200/aluminum++casting+and+pattern+25%252C+38.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipyQRaLyDa5xsTKCU3bLfdHVpb392_9vpVeA2Q99GOtKrSNUSwzCaXbVV4R8O4xxhqCEPWIlKmNeAQCSbUMbIwl1eoXwPzqOMTNb8x8Ess1HwEQmTdbs6jHGOj-RNveNmqAs05S6g9e3Lo/s1600/aluminum+casting+25%252C+38+.jpg"><img style="WIDTH: 163px; HEIGHT: 109px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5714669548204308642" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipyQRaLyDa5xsTKCU3bLfdHVpb392_9vpVeA2Q99GOtKrSNUSwzCaXbVV4R8O4xxhqCEPWIlKmNeAQCSbUMbIwl1eoXwPzqOMTNb8x8Ess1HwEQmTdbs6jHGOj-RNveNmqAs05S6g9e3Lo/s200/aluminum+casting+25%252C+38+.jpg" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-12145804895194757732012-02-01T15:32:00.000-08:002012-02-02T07:24:36.230-08:00Aluminum diving plaque, foundry sand castingThis is a casting I made a few months ago as a gift for my sister. She is very passionate about scuba diving so I thought she might like this aluminum casting. I decided to make a round <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">pattern </a>for this casting and I used 9mm MDF as a base for the images and letters.<br />I started by using my electric router shaping an accurate radius from the 9mm MDF.<br />For this <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">pattern </a>I was trying to create a maritime/diving theme so for the plaque frame I used some plastic rope glued around the <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">pattern</a>.<br />After the rope was in place I used a filler to create a "draft" (angle), draft in sand casting means to create an angle so the pattern will not break the sand mould when lifting it out of the <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">flask</a>.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_aTDOEyf_9b4EYFf1KtlkLlSYENY-T_t4rdup3JfmBXFUXvsp7oUVJEIaAzi1uc2f7J1g7BH3TOEI1PiGb3-3eAoiFzD2RtW3yGyPcgaZkK2_nPbcMFz32IaHW-m7P_W11Y4GU-O5y2jX/s1600/diving+plaque+mdf+base.JPG"><img style="WIDTH: 135px; HEIGHT: 86px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704319819954002322" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_aTDOEyf_9b4EYFf1KtlkLlSYENY-T_t4rdup3JfmBXFUXvsp7oUVJEIaAzi1uc2f7J1g7BH3TOEI1PiGb3-3eAoiFzD2RtW3yGyPcgaZkK2_nPbcMFz32IaHW-m7P_W11Y4GU-O5y2jX/s200/diving+plaque+mdf+base.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvl41XhPKkVWYbgdvG-_Zea7FgO0RAVLcDyH5j4lfeOhUxjGNTB3FeUds2vD4A_0o5cVzm25zKP92JaiZYgDk4L-ljfwLTyGRXSXZrpVHij79dGKVCQeVj8T1J-syfIy6MZEy20sx2kb6I/s1600/casting+pattern6.JPG"><img style="WIDTH: 151px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704319835035875986" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvl41XhPKkVWYbgdvG-_Zea7FgO0RAVLcDyH5j4lfeOhUxjGNTB3FeUds2vD4A_0o5cVzm25zKP92JaiZYgDk4L-ljfwLTyGRXSXZrpVHij79dGKVCQeVj8T1J-syfIy6MZEy20sx2kb6I/s200/casting+pattern6.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi67O5zy7Si3z5Fctkxbxws4IehrvNjZeK-nW5TfTD0x-XSTbwebg69lF9Opk_UfYkec69surPhi5OgEOzCQczLkGzkmeNbysYRE5kVsCab5W4ddJ03rDwvi3Ck1PESBwrTJewloKquXGoq/s1600/casting+pattern7.JPG"><img style="WIDTH: 149px; HEIGHT: 83px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704319830130901234" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi67O5zy7Si3z5Fctkxbxws4IehrvNjZeK-nW5TfTD0x-XSTbwebg69lF9Opk_UfYkec69surPhi5OgEOzCQczLkGzkmeNbysYRE5kVsCab5W4ddJ03rDwvi3Ck1PESBwrTJewloKquXGoq/s200/casting+pattern7.JPG" /></a><br />After the pattern base was ready I started designing the layout of the letters and images. For the letters I used children sticky foam letters, the letters works very well I used them before when I made my <a href="http://www.flamingfurnace.com/2011/04/flamingfurnacecom-aluminum-plaque.html">FlamingFurnace plaque</a> casting. The images I got and printed are from the Internet, I glued them to 3mm cardboard and cut out the shape after glue dried. I live near the sea so from time to time my son collects shells on the beach so I used a few of them for this casting. The "challenging" shell was the spiral shape shell because I had to create the draft around it. I had to grind the base nice and flat to achieve that so I used my light-duty grinder and it was perfect for the job. At this stage it was just a case of re-arranging and marking every item to the exact location on the plaque. Gluing all the parts, creating a draft around each item with filler and finally and most important thing was to give the plaque pattern two coats of clear varnish. The varnish will prevent the sand from sticking to the pattern during the sand moulding process.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdD8w89MRWpU2b8o9hOoTleTP3gPWBJZTfT6Y7Xe_DOiVz2rheWIA4VA8ekrvEX87oqZcCRLRq4XGsn4AFcsAhACMg3cIbAmsnZXtQHhiKwVuXmHkiK_0hBVwjfnNjLiCmZyIQfMnbbKhN/s1600/casting+pattern2.JPG"><img style="WIDTH: 120px; HEIGHT: 78px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704324992913039394" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdD8w89MRWpU2b8o9hOoTleTP3gPWBJZTfT6Y7Xe_DOiVz2rheWIA4VA8ekrvEX87oqZcCRLRq4XGsn4AFcsAhACMg3cIbAmsnZXtQHhiKwVuXmHkiK_0hBVwjfnNjLiCmZyIQfMnbbKhN/s200/casting+pattern2.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIFB_YbTcfdWhLp-wCRdHNRrBmacho8VeRhbBZtWXn7uaVBAJcFjohnumvGRF1xx-yqaAvkQgqXjyXeba-4Xvi20D1lSgII_dryl6COzSp_yxHz_7nIQ7Y8Zd_1W-bgXevW_61iomIn3ej/s1600/casting+pattern3.JPG"><img style="WIDTH: 121px; HEIGHT: 77px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704324995269290674" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIFB_YbTcfdWhLp-wCRdHNRrBmacho8VeRhbBZtWXn7uaVBAJcFjohnumvGRF1xx-yqaAvkQgqXjyXeba-4Xvi20D1lSgII_dryl6COzSp_yxHz_7nIQ7Y8Zd_1W-bgXevW_61iomIn3ej/s200/casting+pattern3.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixhngQ4im4PiAVBFY-HU5Bwbe3Kj2uOE7tCMLyTDBLLPrDBQzbxrFwzY6t1krlAXinWB4CCV2d9YGSAz3hDWrK-TBKn4QuGk3TbyVjjko3QxzMwgrqeM8uvd0k7dLOwOjDWRhBwheJumaw/s1600/aluminum+diving+plaque+diver+images.JPG"><img style="WIDTH: 127px; HEIGHT: 79px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704326132417406946" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixhngQ4im4PiAVBFY-HU5Bwbe3Kj2uOE7tCMLyTDBLLPrDBQzbxrFwzY6t1krlAXinWB4CCV2d9YGSAz3hDWrK-TBKn4QuGk3TbyVjjko3QxzMwgrqeM8uvd0k7dLOwOjDWRhBwheJumaw/s200/aluminum+diving+plaque+diver+images.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKKVO1Y7-Cu1GRotc3Ehr28SW9W5JaLan9FR1Nwj_AO2nf0GeDYgLNAZMPRkwl_JkL2mxhqXHT83I7b0E7VQdksUextk_BYqYh6RX0B8u9zRgsZjPtqifpKVH0RJaL1JbPAfRGZoSBlbWv/s1600/casting+pattern4.JPG"><img style="WIDTH: 111px; HEIGHT: 79px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704325021067959330" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKKVO1Y7-Cu1GRotc3Ehr28SW9W5JaLan9FR1Nwj_AO2nf0GeDYgLNAZMPRkwl_JkL2mxhqXHT83I7b0E7VQdksUextk_BYqYh6RX0B8u9zRgsZjPtqifpKVH0RJaL1JbPAfRGZoSBlbWv/s200/casting+pattern4.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMGTjKksjRp1GZj0xUENEh76DWheMP5BkvohIUHm2hLUeZhrWFg-WKCtGHS2FYO_nF9blCA5_vjHtydVJaOc_cSxHVJbw7SsesqSoTXGJF1jGc3oDH6lRnr9CfA5wOY0T9no9X2oxjnMzO/s1600/Diving+plaque+foundry+pattern+is+ready.JPG"><img style="WIDTH: 128px; HEIGHT: 86px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704328188206086722" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMGTjKksjRp1GZj0xUENEh76DWheMP5BkvohIUHm2hLUeZhrWFg-WKCtGHS2FYO_nF9blCA5_vjHtydVJaOc_cSxHVJbw7SsesqSoTXGJF1jGc3oDH6lRnr9CfA5wOY0T9no9X2oxjnMzO/s200/Diving+plaque+foundry+pattern+is+ready.JPG" /></a><br />The sand moulding part was easy and successful without any sand breaking issues or other moulding problems. For this moulding I used <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">Petrobond</a> sand because I wanted to achieve a fine finishing for this specific plaque casting.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjM8rGTSlhPUHjhvd05Hf_8ivTxwBytTplxLr6x9QJ_wP7RfgleA1QZoStPnqRn3gQXXfuKeZyYm9Ht4AnKzdeq-_F15zF2hYhV9mhvMFNOFjaUt7s8led_IG-LwU95aAQGSWV44AmcuCtN/s1600/aluminum+foundry%252C+diving+plaque%252C+sand+mould+stages.JPG"><img style="WIDTH: 135px; HEIGHT: 95px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704331730134790130" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjM8rGTSlhPUHjhvd05Hf_8ivTxwBytTplxLr6x9QJ_wP7RfgleA1QZoStPnqRn3gQXXfuKeZyYm9Ht4AnKzdeq-_F15zF2hYhV9mhvMFNOFjaUt7s8led_IG-LwU95aAQGSWV44AmcuCtN/s200/aluminum+foundry%252C+diving+plaque%252C+sand+mould+stages.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMEn6Dj1zHj2D2HhlrsYd0Qp-G2I4suCs9Iuwzp6GgMqeQmaRz0yDtuPKK5YauggB78PdG8Mopvinj_9MqOjiVJNgSUbI0h2DCGg9aaO18PRUevnCLoQrgL9kVpm26VKePKWFhaO2C9z4B/s1600/plaque+pattern+in+flask.JPG"><img style="WIDTH: 129px; HEIGHT: 87px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704331791149890162" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMEn6Dj1zHj2D2HhlrsYd0Qp-G2I4suCs9Iuwzp6GgMqeQmaRz0yDtuPKK5YauggB78PdG8Mopvinj_9MqOjiVJNgSUbI0h2DCGg9aaO18PRUevnCLoQrgL9kVpm26VKePKWFhaO2C9z4B/s200/plaque+pattern+in+flask.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvZX1QeNMisNH48yo07r-0xHcLpkDvYVOvVqh-i-slLeN55M9DmNLQdCWg372L4bGNFq_F7dkrZ5q3w-N6oH0dQqYseRGoMvu_9dzy9byu4z9ByUr9dSXYPzyl043lkQGlzTHbIiKXecCd/s1600/plaque+sand+mould.JPG"><img style="WIDTH: 132px; HEIGHT: 87px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704331734047298290" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvZX1QeNMisNH48yo07r-0xHcLpkDvYVOvVqh-i-slLeN55M9DmNLQdCWg372L4bGNFq_F7dkrZ5q3w-N6oH0dQqYseRGoMvu_9dzy9byu4z9ByUr9dSXYPzyl043lkQGlzTHbIiKXecCd/s200/plaque+sand+mould.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHxPnej21teiqc-PoP1qVcxOn-YnNApXb_tjiJG_EqI9yxC0dz-nAm_BdEv1Nyxg_UXz2nKNdzStrT53PSlMf4FfiOHPCECO_2M62j92gLmJscN1pbBVvX2TJeEyXb_8p7bivPzFVpOwUV/s1600/sand+moulding+gate+sprue+and+riser.JPG"><img style="WIDTH: 120px; HEIGHT: 89px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704331763114178258" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHxPnej21teiqc-PoP1qVcxOn-YnNApXb_tjiJG_EqI9yxC0dz-nAm_BdEv1Nyxg_UXz2nKNdzStrT53PSlMf4FfiOHPCECO_2M62j92gLmJscN1pbBVvX2TJeEyXb_8p7bivPzFVpOwUV/s200/sand+moulding+gate+sprue+and+riser.JPG" /></a><br />I used a large wooden flask with inner support ribs for this casting. As always I add a sprue and riser extension as it works very well and prevents aluminum casting shrinkage issues.<br />After opening the flask and removing the moulding sand I was really blown away at how great and detailed the plaque turned out.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlustLoZ0ARO5ke113d1NrzD-7xLeK_H9NdKpNEiPKkH1D7VUzxzCcKH6ApGXaY25Z91_8aZk2p-JA-5CJ_RuBKmE-sZcJqbfhhg3tBN0jV-OYBsSt2FQjFblXujKFj7PcJneVseZZ9T1M/s1600/aluminum+flask%252C+casting+cooling.JPG"><img style="WIDTH: 119px; HEIGHT: 81px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704333710632311522" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlustLoZ0ARO5ke113d1NrzD-7xLeK_H9NdKpNEiPKkH1D7VUzxzCcKH6ApGXaY25Z91_8aZk2p-JA-5CJ_RuBKmE-sZcJqbfhhg3tBN0jV-OYBsSt2FQjFblXujKFj7PcJneVseZZ9T1M/s200/aluminum+flask%252C+casting+cooling.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAdeb0-5RzjP6CfSB611mUHA0m3WbFAmEQ9NYZsr16sE0XNe6uxBfMgBKShmQK1Q2AvFSUIsWRYOF1BYfoyH_Z_xFc28BsggVi0gfL07o55usq8jN78Z8rWdlYjvyJJZXTpZ4Aof_s-fX3/s1600/first+look+at+the+aluminum+casting.JPG"><img style="WIDTH: 118px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704333722526083666" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAdeb0-5RzjP6CfSB611mUHA0m3WbFAmEQ9NYZsr16sE0XNe6uxBfMgBKShmQK1Q2AvFSUIsWRYOF1BYfoyH_Z_xFc28BsggVi0gfL07o55usq8jN78Z8rWdlYjvyJJZXTpZ4Aof_s-fX3/s200/first+look+at+the+aluminum+casting.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBgkFzbFz9OG59YMgwqe_LhbU3j45r379yHsFiUIInoUWfen2595nbxGAIk-oi7OGXyIwZsl3wUM4NASBKs5-a5_tagBXCo9Arfn7054425o5PH6MrytbQ65f8xLYRZW_Q8g_qf3UNZyc1/s1600/aluminum+diving+plaque+clean.JPG"><img style="WIDTH: 116px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704333727741904594" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBgkFzbFz9OG59YMgwqe_LhbU3j45r379yHsFiUIInoUWfen2595nbxGAIk-oi7OGXyIwZsl3wUM4NASBKs5-a5_tagBXCo9Arfn7054425o5PH6MrytbQ65f8xLYRZW_Q8g_qf3UNZyc1/s200/aluminum+diving+plaque+clean.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWAZzwBl4Mf4s5PSX8Qdw1IWntsadbXQqxmVQqgKfd1A2hNJ1pFe1xVkIPjnMQIGxvJwzWeMG0bA-MKaLm3DBAIx-IVj6hNQvFRGbK3_h-owoo9QXJThQI6ByF8j2j7G89vM3a4ZnVm9ke/s1600/aluminum+plaque+size.JPG"><img style="WIDTH: 126px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704338855789903570" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWAZzwBl4Mf4s5PSX8Qdw1IWntsadbXQqxmVQqgKfd1A2hNJ1pFe1xVkIPjnMQIGxvJwzWeMG0bA-MKaLm3DBAIx-IVj6hNQvFRGbK3_h-owoo9QXJThQI6ByF8j2j7G89vM3a4ZnVm9ke/s200/aluminum+plaque+size.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjepC5ORq1VFZVSjm8nwLlbkUskOPLRWncdbDmAnB-phqF9-_5O0gVS0R1IxcUs3o5hyphenhyphenHeVBS8dYaHIbzhyphenhyphenXURpCBrznrnOgR9okf_mr5acNsswV0McFb1EsbQCv85ICkaSS39NDtOFN26T/s1600/casting+pattern%252C+aluminum+casting.JPG"><img style="WIDTH: 128px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704338195588774386" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjepC5ORq1VFZVSjm8nwLlbkUskOPLRWncdbDmAnB-phqF9-_5O0gVS0R1IxcUs3o5hyphenhyphenHeVBS8dYaHIbzhyphenhyphenXURpCBrznrnOgR9okf_mr5acNsswV0McFb1EsbQCv85ICkaSS39NDtOFN26T/s200/casting+pattern%252C+aluminum+casting.JPG" /></a><br />The next part was to cut off the <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">sprue and riser </a>and clean a bit of "flash" (excess aluminum) around the <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">pattern</a> with a metal file. <span style="color:#000099;"><u>This is an important tip: aluminum alloy is soft metal and can be scratched and damaged very easily so when working with a vice its always a good idea to place the aluminum casting in a cloth and not directly in the vice, a cloth will prevent ruining your hard work.</u></span> The only casting part that I polished was the letters, diver images and I semi polished the shells. The image with the spirit level below is just to show how flat the back of the casting plaque is with zero shrinkage thanks to the large <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">sprue and riser</a>.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_p4UNziyUwHERMuJuuFFUy1gfUgZ69rrWSG8Ri8xu2OvqqRMmUfl9ldj2txv0QTdv_onnDDe6cFfpjtaEW5n-sTcEUw7ElOlTVa1cRTIA7GxermV0LyZAtX-bvR-vB8XyOkvNOO86Ev38/s1600/aluminum+plaque%252C+cutting+off+sprue+and+riser.JPG"><img style="WIDTH: 120px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704335732938740594" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_p4UNziyUwHERMuJuuFFUy1gfUgZ69rrWSG8Ri8xu2OvqqRMmUfl9ldj2txv0QTdv_onnDDe6cFfpjtaEW5n-sTcEUw7ElOlTVa1cRTIA7GxermV0LyZAtX-bvR-vB8XyOkvNOO86Ev38/s200/aluminum+plaque%252C+cutting+off+sprue+and+riser.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6rbcDgqNSV-6iZ2nuyQD8icnflOr15o0XReOQGTumoIDaW4D95YHO2HRmBIA6afT47rau2TYMYeZjCIK7nc7oXLz-S_0RQtlWbcUe2FHTTdm7XM5_sEBIVew0LEdqiz34rFFFDeeW3mMr/s1600/aluminum+sprue+and+riser+cut+off.JPG"><img style="WIDTH: 115px; HEIGHT: 84px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704335741504704546" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6rbcDgqNSV-6iZ2nuyQD8icnflOr15o0XReOQGTumoIDaW4D95YHO2HRmBIA6afT47rau2TYMYeZjCIK7nc7oXLz-S_0RQtlWbcUe2FHTTdm7XM5_sEBIVew0LEdqiz34rFFFDeeW3mMr/s200/aluminum+sprue+and+riser+cut+off.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGRmfkKJs-pEcmZzxGNWdYPbtq6SlxN4MSkC2aETIrUzt4dXgkaknhmT8r2snK5G3g3vmzQ1p1VHSP7h7BtxtEJEhs4TwpaR7v1iAdfhJYieoKOV4aFZFopqe8tRClhZY1WcPy7BaG4ief/s1600/grinding+aluminum+flashing.JPG"><img style="WIDTH: 111px; HEIGHT: 86px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704335758488668834" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGRmfkKJs-pEcmZzxGNWdYPbtq6SlxN4MSkC2aETIrUzt4dXgkaknhmT8r2snK5G3g3vmzQ1p1VHSP7h7BtxtEJEhs4TwpaR7v1iAdfhJYieoKOV4aFZFopqe8tRClhZY1WcPy7BaG4ief/s200/grinding+aluminum+flashing.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWEcRABrW8jSo8uY4zCAegWgijIYMxlgvLAKhTzzEhGv6eMSViHagwaUH_5bJmF61Zp1jLAEb18FXP6ttwg8lgSBC-QML-Xsbf63483Yg4wAw89EGUAxImEFaElfl-4JgbObPQClwGixa2/s1600/polishing+aluminum+plaque.JPG"><img style="WIDTH: 114px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704335750783136002" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWEcRABrW8jSo8uY4zCAegWgijIYMxlgvLAKhTzzEhGv6eMSViHagwaUH_5bJmF61Zp1jLAEb18FXP6ttwg8lgSBC-QML-Xsbf63483Yg4wAw89EGUAxImEFaElfl-4JgbObPQClwGixa2/s200/polishing+aluminum+plaque.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4Rtwtvc8yfLU8VRK6nVh1-07PL7oHa-5Bvf04dWpNU1tlMH_uPwyurDuQ7VtdPZydYSqHUn6sO0Uc7aNIhcew_VaWMUYCtqUVYLnNZmFdOsrLKCi8muVVgeEotvNMRdl5L8w3adinrMIm/s1600/flat+aluminum+casting.JPG"><img style="WIDTH: 117px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704340930067872450" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4Rtwtvc8yfLU8VRK6nVh1-07PL7oHa-5Bvf04dWpNU1tlMH_uPwyurDuQ7VtdPZydYSqHUn6sO0Uc7aNIhcew_VaWMUYCtqUVYLnNZmFdOsrLKCi8muVVgeEotvNMRdl5L8w3adinrMIm/s200/flat+aluminum+casting.JPG" /></a><br />The last and final part was to drill two wall mounting holes and paint the aluminum plaque dark blue.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijlfwFy8Sl2Db_5iKmcfd6kCzPk5YYNqdZlIqsRL-AKN1LXDH_lxi_QCNuPQg_qA0CWHxqfDo2Huh8jjL9KWixaL-KezJv1ghyUStwOF_BuKGgrrN2We572NL-cooTAxxQx-BGwuieRyt-/s1600/aluminum+foundry%252C+plaque+casting.JPG"><img style="WIDTH: 155px; HEIGHT: 112px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704335741788171986" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijlfwFy8Sl2Db_5iKmcfd6kCzPk5YYNqdZlIqsRL-AKN1LXDH_lxi_QCNuPQg_qA0CWHxqfDo2Huh8jjL9KWixaL-KezJv1ghyUStwOF_BuKGgrrN2We572NL-cooTAxxQx-BGwuieRyt-/s200/aluminum+foundry%252C+plaque+casting.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijmeqT-zaKGNHxJBUiIwNU4jxqdx0YUPBeckb2HzVbuGVcgROp7dQhKtjQVCbHoDBjqMpPcoZd1hxXZE2i4W1pjP-0E99D32om69YxenIIBVjJqz785uZQ-tzir277Td364kCPA_DHtyKT/s1600/aluminum+foundry%252C+aluminum+casting%252C+diving+plaque.JPG"><img style="WIDTH: 164px; HEIGHT: 114px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704340429626214978" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijmeqT-zaKGNHxJBUiIwNU4jxqdx0YUPBeckb2HzVbuGVcgROp7dQhKtjQVCbHoDBjqMpPcoZd1hxXZE2i4W1pjP-0E99D32om69YxenIIBVjJqz785uZQ-tzir277Td364kCPA_DHtyKT/s200/aluminum+foundry%252C+aluminum+casting%252C+diving+plaque.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhA6h1PxtEzah0wQN8TLPgX7vix7ZtpKUSTNLBF5T50-kd8z9vqaCuq-DDOsULoYUPHEYspqBNC_UWHwabjWxnGCNunHGqrCymM9SlZcQs9FmueuG-s8y6aRqmrcktSPiRW06hrKj2hFX6W/s1600/aluminum+diving+plaque.JPG"><img style="WIDTH: 160px; HEIGHT: 115px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5704340429390423666" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhA6h1PxtEzah0wQN8TLPgX7vix7ZtpKUSTNLBF5T50-kd8z9vqaCuq-DDOsULoYUPHEYspqBNC_UWHwabjWxnGCNunHGqrCymM9SlZcQs9FmueuG-s8y6aRqmrcktSPiRW06hrKj2hFX6W/s200/aluminum+diving+plaque.JPG" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-63488793299672727042012-01-04T12:02:00.000-08:002013-01-04T12:20:29.653-08:00Bell Replica Foundry ProjectThis aluminum bell casting project is relatively easy. As a pattern I used a small brass bell that is hanging on my workshop door for the last few years . <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkns0n9AghS3zAm8P87on08qJa9l4Glsnr52g6rF-wEfWT5sAjyR6tI2ttbwvMfwT9BvB445mvudXS_MhPeZYcyASNQoG_f3vVkKjOmZOafgoDB-M0OQ7RVAKMWm-l8O_f7zA1Q8T62MIq/s1600/bell1.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5592780337696583250" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkns0n9AghS3zAm8P87on08qJa9l4Glsnr52g6rF-wEfWT5sAjyR6tI2ttbwvMfwT9BvB445mvudXS_MhPeZYcyASNQoG_f3vVkKjOmZOafgoDB-M0OQ7RVAKMWm-l8O_f7zA1Q8T62MIq/s200/bell1.JPG" style="cursor: hand; height: 64px; width: 110px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRO3D4jbGVcbHuMI7pj636cgnAb32KbKILv3Td1hxuELF5kl2H-2ML58Wzyi0gWbEA3agD98ejsB6t9q_uaikT1BdFFBJS89PxFisqy_cHAL1n2E9OVGBAx7dJhOwVLGkVlR5D1dVoRaPP/s1600/bell2.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5592780334954803058" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRO3D4jbGVcbHuMI7pj636cgnAb32KbKILv3Td1hxuELF5kl2H-2ML58Wzyi0gWbEA3agD98ejsB6t9q_uaikT1BdFFBJS89PxFisqy_cHAL1n2E9OVGBAx7dJhOwVLGkVlR5D1dVoRaPP/s200/bell2.JPG" style="cursor: hand; height: 65px; width: 103px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8cNObioDPQiKKwOU4ZIzZ0Idfkc0m2K9EENzPYxuudlHRVZ9QCRcnTYNP9C59hV-RAymlvzpmoiFtxHPHrVMUeXCN7GnrVZS5pI3t4D1WWruPVn2D4IP56O5U_xaC0YwhAcsZkByAjkLm/s1600/bell11.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5592780338520654994" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8cNObioDPQiKKwOU4ZIzZ0Idfkc0m2K9EENzPYxuudlHRVZ9QCRcnTYNP9C59hV-RAymlvzpmoiFtxHPHrVMUeXCN7GnrVZS5pI3t4D1WWruPVn2D4IP56O5U_xaC0YwhAcsZkByAjkLm/s200/bell11.JPG" style="cursor: hand; height: 64px; width: 104px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOJcb2D1LqWFBJb20HFrmB4KoBLVewhwvf9Ajk8r-Bzq3W2I-Ysx4ZIK3vtncpGItRqjd3t6pT7HY70kM1UUr3KHExBvICkf7QewVbY9oIskfiHHiTl-GF4vcopXcMTzoTEVd5zNNMoDu6/s1600/sand+casting+aluminum+bell.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5592809686061813906" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOJcb2D1LqWFBJb20HFrmB4KoBLVewhwvf9Ajk8r-Bzq3W2I-Ysx4ZIK3vtncpGItRqjd3t6pT7HY70kM1UUr3KHExBvICkf7QewVbY9oIskfiHHiTl-GF4vcopXcMTzoTEVd5zNNMoDu6/s200/sand+casting+aluminum+bell.JPG" style="cursor: hand; height: 74px; width: 93px;" /></a> Making the mould is a very easy process but the tricky part is getting all the aluminum to fill the mould cavity. The bell pattern is about 3mm thick and as I thought it didn't fill properly the first pour. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjk_LYKShLZFm9dbC0cwmndg5rC1FKw62UIu97jyk5WWF9tupSA0dOnypmtcw-4VPt9faSNGyT38YhP6Mcnqm2NHc0bMwaBVNtcg-Ix1ZPEAqz0z4j2Y-PeJeZKIIH1YRqV83TLaZ6Oy_JJ/s1600/bell13.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5592809915904803266" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjk_LYKShLZFm9dbC0cwmndg5rC1FKw62UIu97jyk5WWF9tupSA0dOnypmtcw-4VPt9faSNGyT38YhP6Mcnqm2NHc0bMwaBVNtcg-Ix1ZPEAqz0z4j2Y-PeJeZKIIH1YRqV83TLaZ6Oy_JJ/s200/bell13.jpg" style="cursor: hand; height: 63px; width: 99px;" /></a> The second pour I carved some of the sand off the cope part of the mould. This time the sand mould was filled properly. I like the contrast between the aluminum silver shine and the brass. Now I plan to make a back mounting plate for both of the bells. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizlB8fVzByDYlD70ebCdyUfqzPsCKuzkhsmBxmOOYG8k8N85VqvIo6nRNcYaZvLrKat_I97aZwoPS7IT3jfh9Ca_n5K4tQ27L-1Wk3BHCnpGlnPPOsGqNV5o2f0zs0EDS3aNCJo6sn1p99/s1600/bell17.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5592781689166493442" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizlB8fVzByDYlD70ebCdyUfqzPsCKuzkhsmBxmOOYG8k8N85VqvIo6nRNcYaZvLrKat_I97aZwoPS7IT3jfh9Ca_n5K4tQ27L-1Wk3BHCnpGlnPPOsGqNV5o2f0zs0EDS3aNCJo6sn1p99/s200/bell17.JPG" style="cursor: hand; height: 76px; width: 105px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7vGS6fvQ1f9RPz3fLPheFxHUY9AK6RBVTJYogBBQ5SeRJpFdCxGda37k93ScVgnasX_tnnv2JX2IoFUrJu7D3X8y2W1XomXlSdxY1S3DKMXxQ7QBplMfNCpYSKly6mlthX4Gm_mkumuNC/s1600/bell18.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5592781689024616850" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7vGS6fvQ1f9RPz3fLPheFxHUY9AK6RBVTJYogBBQ5SeRJpFdCxGda37k93ScVgnasX_tnnv2JX2IoFUrJu7D3X8y2W1XomXlSdxY1S3DKMXxQ7QBplMfNCpYSKly6mlthX4Gm_mkumuNC/s200/bell18.JPG" style="cursor: hand; height: 76px; width: 114px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTAG5i7gRRwTPRP7KGqppzzaOiHjO16ETX80f4X0BrvnhxVOaUbYuf7HDkbXIaaK9cxNi_XHoOt18fl0mRp245WnE5tl9WEqCnkgSuaEFB43bmTIxocxjUyHDTUq71vqW5EOZiLF3mbVay/s1600/bell21.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5592781694289260722" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTAG5i7gRRwTPRP7KGqppzzaOiHjO16ETX80f4X0BrvnhxVOaUbYuf7HDkbXIaaK9cxNi_XHoOt18fl0mRp245WnE5tl9WEqCnkgSuaEFB43bmTIxocxjUyHDTUq71vqW5EOZiLF3mbVay/s200/bell21.JPG" style="cursor: hand; height: 84px; width: 115px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJq7DwDw9akZTKy-_mdkbSGahtuAd-bgXQpmPS5TYy6R2hERw5cZsRJ7IqWnvE1m6gCeREhNwzfA-SeGXPMRy7Ct0BtIj8A_ZkKkUuWGJmHVFkxlTOo8qda44iWLO1rCApchg4hfu_YZqb/s1600/bell20.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5592810423675727026" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJq7DwDw9akZTKy-_mdkbSGahtuAd-bgXQpmPS5TYy6R2hERw5cZsRJ7IqWnvE1m6gCeREhNwzfA-SeGXPMRy7Ct0BtIj8A_ZkKkUuWGJmHVFkxlTOo8qda44iWLO1rCApchg4hfu_YZqb/s200/bell20.JPG" style="cursor: hand; height: 81px; width: 116px;" /></a><span style="font-size: 0;"></span>Using my gas burner for the foundry it takes about 35-45 min for the aluminum to melt. I use all the scrap sprue and risers from the other castings, No aluminum goes to waste ;-) <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjKkvyCzaewRdussxVYddmn9qBdhYn2CL6IcNEToW9G7d4jEa_-P6M9uGqQr_UpPgqXdT80DDNGoHDaAm9v73hueq-0P3qrUoXuWW3h0vBsSzmQQc8msnTbDcYyCASzOFB0vnPEMtZsHOD/s1600/bell15.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5592782794546395410" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjKkvyCzaewRdussxVYddmn9qBdhYn2CL6IcNEToW9G7d4jEa_-P6M9uGqQr_UpPgqXdT80DDNGoHDaAm9v73hueq-0P3qrUoXuWW3h0vBsSzmQQc8msnTbDcYyCASzOFB0vnPEMtZsHOD/s200/bell15.JPG" style="cursor: hand; height: 64px; width: 110px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh40g2GIwvQqFErL03ARIPyPNb0s0uwNFA3nrUdHB04xaR5wqjpi7Cf6BPt-nY-qPG5ez7ucMB-djaFeCkp4wBFDiyNK4ltzCZ9yyx6Cv43OSirjh1cNFrehEdd_RgXX-R93uL0qJ32W9TN/s1600/bell19.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5592782810347472018" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh40g2GIwvQqFErL03ARIPyPNb0s0uwNFA3nrUdHB04xaR5wqjpi7Cf6BPt-nY-qPG5ez7ucMB-djaFeCkp4wBFDiyNK4ltzCZ9yyx6Cv43OSirjh1cNFrehEdd_RgXX-R93uL0qJ32W9TN/s200/bell19.JPG" style="cursor: hand; height: 65px; width: 124px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQHmL4XuYkqXnTL70d5-rsI733M7gVA2RxmJcUmHyNq9kH12zZen_OV_P6ZfWpF-SOueKz39uBAEUZ3a23DKkAObNGbm12Ra9XEudSAfchbY1-Z4xGDN4rz4njwlzllgOLo9Bwbop5TRiS/s1600/bell14.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5592782798641406498" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQHmL4XuYkqXnTL70d5-rsI733M7gVA2RxmJcUmHyNq9kH12zZen_OV_P6ZfWpF-SOueKz39uBAEUZ3a23DKkAObNGbm12Ra9XEudSAfchbY1-Z4xGDN4rz4njwlzllgOLo9Bwbop5TRiS/s200/bell14.JPG" style="cursor: hand; height: 65px; width: 119px;" /></a></div>
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<u>Aluminum bell casting video:</u> <iframe frameborder="0" height="293" src="http://www.youtube.com/embed/vJBM3oz6hYk?rel=0" title="YouTube video player" width="350"></iframe>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-16897018040999864602011-12-30T17:16:00.000-08:002013-04-17T13:40:54.024-07:00Oil Bonded Sand Cating Large Aluminum SkullIn this aluminum casting I made a replica of a decorative plastic skull that I bought for €10. For the sand moulding I used <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">petrobond</a> and carved around the pattern. The main problem with the skull was its shape. I used filler to smooth "problematic" angles of the skull so that way it would be easier to remove the pattern without breaking the sand impression.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbBAKGPZOtH-ZMylKSL6eV3mEe63f7u2TfYQyd6Hm8TR7YiHNLRzQ_vbvof9-Ye9bZUuH-TfmZVs0VZ32LmaxpntGoahgvd_cSXp18nUwWb1j4ToQPyehtDzI1BwHddAIqVsRBM7Jyogqq/s1600/foundry+flask+1.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692101595907459938" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbBAKGPZOtH-ZMylKSL6eV3mEe63f7u2TfYQyd6Hm8TR7YiHNLRzQ_vbvof9-Ye9bZUuH-TfmZVs0VZ32LmaxpntGoahgvd_cSXp18nUwWb1j4ToQPyehtDzI1BwHddAIqVsRBM7Jyogqq/s200/foundry+flask+1.JPG" style="cursor: hand; height: 84px; width: 125px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiRauqNcoEaWNL57s7NxxuoCxLBc8RQ9kisOu3Z0saXC3Qy1KTva9Q5zvm87AM4a7BBLnHxrJ-pNxAhIqnLFSFtJmjVbT6FAjFu3oRTprE_-sCMVTTIy1E0U6KXaT1ALzzYs0PD9R4NxiL/s1600/foundry+flask+4.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692101610929186978" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiRauqNcoEaWNL57s7NxxuoCxLBc8RQ9kisOu3Z0saXC3Qy1KTva9Q5zvm87AM4a7BBLnHxrJ-pNxAhIqnLFSFtJmjVbT6FAjFu3oRTprE_-sCMVTTIy1E0U6KXaT1ALzzYs0PD9R4NxiL/s200/foundry+flask+4.JPG" style="cursor: hand; height: 77px; width: 124px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBq7nn6n1_2uyH7p8w4_a_OHBVbihb8N-gFND8H4_vmPxNd3GwibC5KVwC9lE6s1K5vfqPX9avRn_31c5g2209pLX0zNmahMrmq3MakfFbxeB57_BuUYQj8zAxYV5twFuyeZ0xfMKOsw7D/s1600/foundry+flask+6.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692100310344634226" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBq7nn6n1_2uyH7p8w4_a_OHBVbihb8N-gFND8H4_vmPxNd3GwibC5KVwC9lE6s1K5vfqPX9avRn_31c5g2209pLX0zNmahMrmq3MakfFbxeB57_BuUYQj8zAxYV5twFuyeZ0xfMKOsw7D/s200/foundry+flask+6.JPG" style="cursor: hand; height: 78px; width: 121px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimw2HPJvLbCBUujENX6omQXrl8tp8Tn11oiPSt41tMGMAzIm2ZvMi4gGLjXK4RbH40-FKdDwxrJ8nF1SUJmQ_Nrd5n1NCD2XNdXd-czSurNZnGmaXTIywdznU0nYUli77JeNRgCp8T4i4d/s1600/foundry+flask+5.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692101617247666754" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimw2HPJvLbCBUujENX6omQXrl8tp8Tn11oiPSt41tMGMAzIm2ZvMi4gGLjXK4RbH40-FKdDwxrJ8nF1SUJmQ_Nrd5n1NCD2XNdXd-czSurNZnGmaXTIywdznU0nYUli77JeNRgCp8T4i4d/s200/foundry+flask+5.JPG" style="cursor: hand; height: 80px; width: 122px;" /></a><br />
For this casting I also built a new wooden <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">Flask</a> because of the large size of the skull. I decided to reduce the weight of the aluminum skull by creating a hollow core. To form the core I just used an empty can of corn instead of making the traditional sand core.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_teToWCM0gv6CXsMFFsR9GcHVpiope-XpeUI2iFgX_rsaiwQAqsy_V1wXZ_M9PuHk3ntGix_5Zn-YzK9YpdgVfWGHTj3l2hPiOhZdrxlxODg9N-8ngyT6gHQ3lGQgLlDKHmrtG3uVD6dS/s1600/sand+casting+core.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692100310470607506" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_teToWCM0gv6CXsMFFsR9GcHVpiope-XpeUI2iFgX_rsaiwQAqsy_V1wXZ_M9PuHk3ntGix_5Zn-YzK9YpdgVfWGHTj3l2hPiOhZdrxlxODg9N-8ngyT6gHQ3lGQgLlDKHmrtG3uVD6dS/s200/sand+casting+core.JPG" style="cursor: hand; height: 79px; width: 123px;" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7sXJsxcdkdIAUOk1RYt1fO5ujiGRZwwNt3OdcPXtj6qVVMMLkyI9gwLW9SLTKiTtsM5tjGoceOFGa6s-v0CqX_PNBSJgVgJZ4x98Bus3X2Y7JFaRKYZigi3iHHsFWWDFJFscXcx_eZWjm/s1600/aluminum+casting+cooling.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692100315823609202" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7sXJsxcdkdIAUOk1RYt1fO5ujiGRZwwNt3OdcPXtj6qVVMMLkyI9gwLW9SLTKiTtsM5tjGoceOFGa6s-v0CqX_PNBSJgVgJZ4x98Bus3X2Y7JFaRKYZigi3iHHsFWWDFJFscXcx_eZWjm/s200/aluminum+casting+cooling.JPG" style="cursor: hand; height: 82px; width: 142px;" /></a><br />
The casting turned out well the only mistake is did was placing the corn can too high in the sand and that caused holes in the casted skull eye sockets.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcBJfsdTmUbPwyhs0xLxxwYKMGkmeKMqrb7iefCNwphMkTVYZkXtJ__s2nV2QvYMsGLvzZKoZ4UHEwtxK6ZDf3nW_Bbd6ZATdiUkomdpXgz6L03XnmMqUQyYzTXOwRvzb5Svr5GBha9cVe/s1600/aluminum+skull+5.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692103713249611986" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcBJfsdTmUbPwyhs0xLxxwYKMGkmeKMqrb7iefCNwphMkTVYZkXtJ__s2nV2QvYMsGLvzZKoZ4UHEwtxK6ZDf3nW_Bbd6ZATdiUkomdpXgz6L03XnmMqUQyYzTXOwRvzb5Svr5GBha9cVe/s200/aluminum+skull+5.JPG" style="cursor: hand; height: 91px; width: 148px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhM8gWcjKAJ-0Bxyk9JG1tZXNdT5CNtZ3ewwhq8H9SYPBsl2-znIXvTLTO15RjsdTkwDw5KMOx_o_0D_T8w15nfwnK2RMC0jsXcD-A7RTDbKRJZqtrHWxtKBCskSZbZpTb05ZLcR3TKPNem/s1600/aluminum+skull+4.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692103710398817522" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhM8gWcjKAJ-0Bxyk9JG1tZXNdT5CNtZ3ewwhq8H9SYPBsl2-znIXvTLTO15RjsdTkwDw5KMOx_o_0D_T8w15nfwnK2RMC0jsXcD-A7RTDbKRJZqtrHWxtKBCskSZbZpTb05ZLcR3TKPNem/s200/aluminum+skull+4.JPG" style="cursor: hand; height: 84px; width: 109px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiOkP1XVmCkXf2A9evLa5CbMbVxkhFwLqpbEq3xTI_HmjpT52V97PiZUxVF2Fr7ZPUtdvcAYVrl6QeYfTUgyJ_lIuuZMtTT2mMZVp0FNMtCcoQTBAGgQKwjMUz61Z0l0F4mexLhfwP8GN6/s1600/aluminum+skull+3.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692103699483574962" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiOkP1XVmCkXf2A9evLa5CbMbVxkhFwLqpbEq3xTI_HmjpT52V97PiZUxVF2Fr7ZPUtdvcAYVrl6QeYfTUgyJ_lIuuZMtTT2mMZVp0FNMtCcoQTBAGgQKwjMUz61Z0l0F4mexLhfwP8GN6/s200/aluminum+skull+3.JPG" style="cursor: hand; height: 83px; width: 113px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5iINDtLdSaC5HgTHY-OrZTscOM-onHElcncE2XTs-OL-UwfqyklAw-3YKXSg0ipRjuP1FnhqTzKGqKQ0xjQVW9fI8v1cSPOqTqXlDl6EVyBh6IEb8rBcH5ByD8DIzcw-jcRQRY599PmyJ/s1600/aluminum+skull+2.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692103698327745442" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5iINDtLdSaC5HgTHY-OrZTscOM-onHElcncE2XTs-OL-UwfqyklAw-3YKXSg0ipRjuP1FnhqTzKGqKQ0xjQVW9fI8v1cSPOqTqXlDl6EVyBh6IEb8rBcH5ByD8DIzcw-jcRQRY599PmyJ/s200/aluminum+skull+2.JPG" style="cursor: hand; height: 82px; width: 126px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipqIH8UJfzP2PKgiK93psI3u9tppYJMlCrksKFcutsB4eEcuClvhalhI3oAyy-WN2DidsFSgDr5DKS60UByB0WR1nXcqMXDUhj9ITlKKXRVYqetxBAZX4jUeBhyphenhyphenrfwiJecrnnL8y8rJtAg/s1600/aluminum+skull+1.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692103695413305154" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipqIH8UJfzP2PKgiK93psI3u9tppYJMlCrksKFcutsB4eEcuClvhalhI3oAyy-WN2DidsFSgDr5DKS60UByB0WR1nXcqMXDUhj9ITlKKXRVYqetxBAZX4jUeBhyphenhyphenrfwiJecrnnL8y8rJtAg/s200/aluminum+skull+1.JPG" style="cursor: hand; height: 83px; width: 116px;" /></a><br />
I made a short video just showing how I removed the can of corn from the skull casting. It's a very easy proccess all that is needed is some sort of pliers to cut and pull the can out of the aluminum skull casting.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhogVfGoXIWvyp8l8PV3HSb2dC_1K1akLhhEO7AJ6MDEC765rXaMlhKL_c3lNHqg6kLCIqSoR8MPS5bFFZv87uoeJ44k4fTpPN8mu-kSaQwhkrvFIcq3-VOdzr77WQp1UfgyiW068RYu_Pu/s1600/aluminum+skull+7.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692104962262516914" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhogVfGoXIWvyp8l8PV3HSb2dC_1K1akLhhEO7AJ6MDEC765rXaMlhKL_c3lNHqg6kLCIqSoR8MPS5bFFZv87uoeJ44k4fTpPN8mu-kSaQwhkrvFIcq3-VOdzr77WQp1UfgyiW068RYu_Pu/s200/aluminum+skull+7.JPG" style="cursor: hand; height: 80px; width: 116px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjE9V_Z3imbEiROwi3WzTRixH9BBB366kVi_vdWq_umDB2BRxCdefjSW500VNmzID3uEKQlUr7J01C58fSSLYadanOdY_BOsJTQ7F8XNEKf0GSN0HWJBReKVkgFS1ewtklN5hZAUoAXe_zJ/s1600/aluminum+skull+8.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692104962176187522" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjE9V_Z3imbEiROwi3WzTRixH9BBB366kVi_vdWq_umDB2BRxCdefjSW500VNmzID3uEKQlUr7J01C58fSSLYadanOdY_BOsJTQ7F8XNEKf0GSN0HWJBReKVkgFS1ewtklN5hZAUoAXe_zJ/s200/aluminum+skull+8.JPG" style="cursor: hand; height: 79px; width: 110px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmJQNlfFk0AwkW2ZVTZtELKy54K7nz_UCtWUJv3CDESDffX1ua14wC-4UT859lOSerOf5iNJrnJ8W5LQiZOp-FNG-urUQNS14mFGuGEu1InQqMQDq-o95EJTs0IlhyphenhyphenlvNC_vVjWc5l9-4H/s1600/DSCN0210+%2528Small%2529.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692104968352695282" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmJQNlfFk0AwkW2ZVTZtELKy54K7nz_UCtWUJv3CDESDffX1ua14wC-4UT859lOSerOf5iNJrnJ8W5LQiZOp-FNG-urUQNS14mFGuGEu1InQqMQDq-o95EJTs0IlhyphenhyphenlvNC_vVjWc5l9-4H/s200/DSCN0210+%2528Small%2529.jpg" style="cursor: hand; height: 76px; width: 111px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgE-1KkM3n1mHERXp7UHlbcnZGYPZ8-GgVFANXmgLD5KGNV0M4n-Cm7BZCGuRmolGdm7mtGYxgl5lgWxZIW0Qs8sOZ3r0Iawd7mG8MJTZBtOSxRLE5xPrEi18_HDqi4VkmoP4EKMKQP3wd5/s1600/DSCN0211+%2528Small%2529.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692104972509809282" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgE-1KkM3n1mHERXp7UHlbcnZGYPZ8-GgVFANXmgLD5KGNV0M4n-Cm7BZCGuRmolGdm7mtGYxgl5lgWxZIW0Qs8sOZ3r0Iawd7mG8MJTZBtOSxRLE5xPrEi18_HDqi4VkmoP4EKMKQP3wd5/s200/DSCN0211+%2528Small%2529.jpg" style="cursor: hand; height: 80px; width: 133px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZI2Jf-tMCZz5aiTE2d0v8TXhsdM5N4a6hBrnW8ku0WdD_PqRK7Xl-ZUcN5TiVj-dIKvbydC6EiTEWM7uubDTkCGjwpEPWedhVLpOsckcsCqEBSj_YKzgtwec5mA-aJLEiiHbrDXrmf1nJ/s1600/DSCN0216+%2528Small%2529.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5692104978825077970" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZI2Jf-tMCZz5aiTE2d0v8TXhsdM5N4a6hBrnW8ku0WdD_PqRK7Xl-ZUcN5TiVj-dIKvbydC6EiTEWM7uubDTkCGjwpEPWedhVLpOsckcsCqEBSj_YKzgtwec5mA-aJLEiiHbrDXrmf1nJ/s200/DSCN0216+%2528Small%2529.jpg" style="cursor: hand; height: 81px; width: 128px;" /></a><br />
Video of me removing the can:<br />
<iframe frameborder="0" height="233" src="http://www.youtube.com/embed/U__mMrml8EQ?rel=0&hd=1" width="400"></iframe>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-44468118634935645612011-11-23T15:33:00.001-08:002012-03-28T12:30:41.347-07:00Green casting sand VS oil bonded sandI <span id="SPELLING_ERROR_0" class="blsp-spelling-corrected">decided</span> after using oil bonded sand <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">(petrobond)</a> to test some homemade <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">green sand</a>. I got some play sand and after doing a bit of <span id="SPELLING_ERROR_2" class="blsp-spelling-corrected">Internet</span> <span id="SPELLING_ERROR_3" class="blsp-spelling-corrected">research</span> I started making the green sand. My goal was to make it at minimum cost and to <span id="SPELLING_ERROR_4" class="blsp-spelling-corrected">achieve</span> semi good casting quality ;-).<br />I started experimenting with small <span id="SPELLING_ERROR_5" class="blsp-spelling-corrected">quantities</span> <span id="SPELLING_ERROR_6" class="blsp-spelling-corrected">measuring</span> first 1KG of sifted and dry play sand. I used a mixer to grind the cat litter (clay) to a powder stage and then sifted 100gr (10% of clay), mixing both <span id="SPELLING_ERROR_8" class="blsp-spelling-corrected">together</span> and after just adding small amounts of water at a time. The <span id="SPELLING_ERROR_9" class="blsp-spelling-corrected">process</span> was very quick and the sand mix was ready after performing the squeeze test.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgWqI9Rzu7m7PNW1qYSmwK0PavrDWrzHT02bfhpRc6Wp0JSuXGsepc3iUxwMRAFhp-44wuOANUuFWOQZ4YHnR4qr_yMKlSQmT3ORgzADtBOFbyL0SxawiJajN5alkiUAwmFGeeYmhebnSz/s1600/green+sand+1.jpg"><img style="WIDTH: 144px; HEIGHT: 97px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5678344586121003058" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgWqI9Rzu7m7PNW1qYSmwK0PavrDWrzHT02bfhpRc6Wp0JSuXGsepc3iUxwMRAFhp-44wuOANUuFWOQZ4YHnR4qr_yMKlSQmT3ORgzADtBOFbyL0SxawiJajN5alkiUAwmFGeeYmhebnSz/s200/green+sand+1.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHTsMoTxcy8uSCadfmYJ6AHegU77vjKy6eRwus2IjKFPr5wPMPEPl52Q9I5HVqENhO8SWRx0bOMGO8iiqW5luaJNQsBpdFTD9i6UzF0n-6sPkxWXuFz3Mqbv4bSsa2ToPbd_F3v8L7exfV/s1600/green+sand+2.jpg"><img style="WIDTH: 154px; HEIGHT: 97px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5678344589637585042" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHTsMoTxcy8uSCadfmYJ6AHegU77vjKy6eRwus2IjKFPr5wPMPEPl52Q9I5HVqENhO8SWRx0bOMGO8iiqW5luaJNQsBpdFTD9i6UzF0n-6sPkxWXuFz3Mqbv4bSsa2ToPbd_F3v8L7exfV/s200/green+sand+2.jpg" /></a><br />My first casting was an aluminum eagle. This was the 12th aluminum eagle I have casted and the result was very promising. No <span id="SPELLING_ERROR_11" class="blsp-spelling-corrected">difference</span> in the quality of the casting from the oil bonded <a href="http://www.flamingfurnace.com/2011/03/aluminum-eagle-sand-casting.html">eagle castings</a>.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_Z8tExkMzBQAXV7BqY5Z9ty5r7IDASrgNsvFg9rEXfHOtOcvG2zm_oHLed3IeBSpGcL9YOUIiPes1_16pgMCZdq_3wvrLFQKPL9sodGAnqfdE5qnxSDKjy_1ITbF8m74aQlL_sj6A8SHQ/s1600/green+sand+casting+1.jpg"><img style="WIDTH: 124px; HEIGHT: 71px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5678345520683752658" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_Z8tExkMzBQAXV7BqY5Z9ty5r7IDASrgNsvFg9rEXfHOtOcvG2zm_oHLed3IeBSpGcL9YOUIiPes1_16pgMCZdq_3wvrLFQKPL9sodGAnqfdE5qnxSDKjy_1ITbF8m74aQlL_sj6A8SHQ/s200/green+sand+casting+1.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6Gee6NhqMVqEIjhU-DRlGrZmHJmEFipK0uU2HhZQQMjnvBALcDnRoYnPk_jdJXTshFEmKxXMHCtGNkU48t44QQzPoEqRHJ41fFcBPdHRal1gFmP14H97OhHIhPlM-bE4ZTBDINLHPuPKh/s1600/green+sand+casting+2.jpg"><img style="WIDTH: 111px; HEIGHT: 72px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5678345518906460994" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6Gee6NhqMVqEIjhU-DRlGrZmHJmEFipK0uU2HhZQQMjnvBALcDnRoYnPk_jdJXTshFEmKxXMHCtGNkU48t44QQzPoEqRHJ41fFcBPdHRal1gFmP14H97OhHIhPlM-bE4ZTBDINLHPuPKh/s200/green+sand+casting+2.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMtz8yWR7dNLuYG-ek-39mL3PnhfStZxYqg5VfRdYVn0yDGxVHqayUepQXaSgA9siVrVBj4EcjZv1_fvgVSnaGGX_UMAji8CvjqbF4hoKZPp6Vn9P2XsAxHkOaaSsENzkJIzWey4-htIxi/s1600/green+sand+casting+4.jpg"><img style="WIDTH: 100px; HEIGHT: 75px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5678345529638439474" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMtz8yWR7dNLuYG-ek-39mL3PnhfStZxYqg5VfRdYVn0yDGxVHqayUepQXaSgA9siVrVBj4EcjZv1_fvgVSnaGGX_UMAji8CvjqbF4hoKZPp6Vn9P2XsAxHkOaaSsENzkJIzWey4-htIxi/s200/green+sand+casting+4.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfSZaqna-086Tmg__CovMIISexOda6TxLmGxUZn4qI545yD4S2XyGplZW3BxqnDNA8h0-bnH7JutK9QNKv3qwqp1YdeRNNeDYpTUYhc4On9fmeD1xNajV2l-2sS82KdD-tjGVb8XroOh10/s1600/green+sand+casting+5.jpg"><img style="WIDTH: 104px; HEIGHT: 75px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5678345532754643106" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfSZaqna-086Tmg__CovMIISexOda6TxLmGxUZn4qI545yD4S2XyGplZW3BxqnDNA8h0-bnH7JutK9QNKv3qwqp1YdeRNNeDYpTUYhc4On9fmeD1xNajV2l-2sS82KdD-tjGVb8XroOh10/s200/green+sand+casting+5.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHV6vqQbSKhARmICqSAXWC2OOmrw6Bqwl9OVGwcxFGM23rUMUue0SLqbtBlGy__B6pRfv_UBukqfp4XP46v0FEppviwbaN70146xI4exEWGuCeLwW9G-NKyekluLswdgs3SxC9v_V7Xx6O/s1600/green+sand+casting+6.jpg"><img style="WIDTH: 118px; HEIGHT: 76px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5678345536768665250" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHV6vqQbSKhARmICqSAXWC2OOmrw6Bqwl9OVGwcxFGM23rUMUue0SLqbtBlGy__B6pRfv_UBukqfp4XP46v0FEppviwbaN70146xI4exEWGuCeLwW9G-NKyekluLswdgs3SxC9v_V7Xx6O/s200/green+sand+casting+6.jpg" /></a><br />I decided to cast a bigger aluminum object this time so I casted my 3rd <a href="http://www.flamingfurnace.com/2011/08/2nd-aluminum-sun-sand-moulding.html">aluminum sun</a>. The quality of the casting in this case was not the same. The oil bonded sand sun casting was with almost zero defects and the green sand casting was with a lot of defects mostly porosity. Perhaps from not ramming the play sand hard enough or from the lack of vent hole but again it's not the worst sand casting. I hung the sun on a garden wall and the defects aren't even noticeable it just needs a bit of sanding and polishing.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEid5tTEr_82wPqFkFKQhm3Bd_MSUIAtZCqtAtHgNP_SdKlEmdi-ILlamoBhPz-Pq_m_X5MXl1njMhVqcZDggdF9cTyxWkSpC3Bno5Wk82-PrgHOie73QYDCdiO0Ph_S0ZHGOgL1_7VV6sEu/s1600/green+sand+casting+7.jpg"><img style="WIDTH: 116px; HEIGHT: 86px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5678346306444504098" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEid5tTEr_82wPqFkFKQhm3Bd_MSUIAtZCqtAtHgNP_SdKlEmdi-ILlamoBhPz-Pq_m_X5MXl1njMhVqcZDggdF9cTyxWkSpC3Bno5Wk82-PrgHOie73QYDCdiO0Ph_S0ZHGOgL1_7VV6sEu/s200/green+sand+casting+7.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhB5nTNLjnZaan4B_MkmEoiu2Sqw5B0Q6iC1I1r-4XpabrYkizU-x9KSLruYuA_6GWQUoErhwXk5ga2zYF-HFI3GFK0UDWifD6VI0vNQJx8mUVzcpB3RfwNS4TcSDJTuE5DD0oDwsdG_50M/s1600/green+sand+casting+8.jpg"><img style="WIDTH: 127px; HEIGHT: 88px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5678346311589896002" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhB5nTNLjnZaan4B_MkmEoiu2Sqw5B0Q6iC1I1r-4XpabrYkizU-x9KSLruYuA_6GWQUoErhwXk5ga2zYF-HFI3GFK0UDWifD6VI0vNQJx8mUVzcpB3RfwNS4TcSDJTuE5DD0oDwsdG_50M/s200/green+sand+casting+8.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiJrcXWcyPA847R5iVYHCN8m06rYjz8xDEWtoKj8BNtqxSDmZMgRpJ6C-C4hmoLgqIDfaB1P4UnaJeVP0M_a8QxdyStpGm1eMM2WhEjoZLqYQQvuNSuPTA18Quw5mPT4c_RmJsyz1UOSfO/s1600/green+sand+casting+9.jpg"><img style="WIDTH: 116px; HEIGHT: 86px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5678346317109501202" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiJrcXWcyPA847R5iVYHCN8m06rYjz8xDEWtoKj8BNtqxSDmZMgRpJ6C-C4hmoLgqIDfaB1P4UnaJeVP0M_a8QxdyStpGm1eMM2WhEjoZLqYQQvuNSuPTA18Quw5mPT4c_RmJsyz1UOSfO/s200/green+sand+casting+9.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwNo9ui8-_E5AjzHMCfdClvN5JgBk4gwPQ4fkAsv_03770C_QxUMyqk8HJlIn-4JObd1IVt8vO7PLNACJSlZTrOzwsaxN2e2DxzHhDmFrSdXWOTiahYlzAw-V57mYLcqjDX9RG_iyodv3D/s1600/green+sand+casting+10.jpg"><img style="WIDTH: 117px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5678346318322798322" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwNo9ui8-_E5AjzHMCfdClvN5JgBk4gwPQ4fkAsv_03770C_QxUMyqk8HJlIn-4JObd1IVt8vO7PLNACJSlZTrOzwsaxN2e2DxzHhDmFrSdXWOTiahYlzAw-V57mYLcqjDX9RG_iyodv3D/s200/green+sand+casting+10.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhC4VBofEy2bqmEE8z5h4wc1hyphenhyphen4HiluLXjbpKAnsYEKvL0qv-qTIDv0lS-L-MGDGWwLN3Xux3C5gUIQpbvFHv2ebjDBJWoFqQ_CZWFLHPpqmTtc4iOMQOtNLmvm04P8bAht7Qr2e6DmfN0A/s1600/nikon1+084+%2528Small%2529.jpg"><img style="WIDTH: 130px; HEIGHT: 86px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5678346326026313810" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhC4VBofEy2bqmEE8z5h4wc1hyphenhyphen4HiluLXjbpKAnsYEKvL0qv-qTIDv0lS-L-MGDGWwLN3Xux3C5gUIQpbvFHv2ebjDBJWoFqQ_CZWFLHPpqmTtc4iOMQOtNLmvm04P8bAht7Qr2e6DmfN0A/s200/nikon1+084+%2528Small%2529.jpg" /></a><br />How oil bonded sand VS green sand:<br />Oil bonded sand produces a better quality casting but is much more <span id="SPELLING_ERROR_13" class="blsp-spelling-corrected">expensive</span> then green sand. Green sand is cheap, easy to make and re-usable. Oil bonded sand is stinky, smokey and stains everything it comes in contact with. Green sand is clean with no smell. Oil bonded sand is much more sticky then green sand. Green sand is alot more <span id="SPELLING_ERROR_14" class="blsp-spelling-corrected">fragile</span> then oil bonded sand.<br />If you are looking for amazing finishing on your casting use oil bonded sand. If you want a cheap solution for casting, for example some heavy machinery parts green sand will do just fine.<br /><br /><u><strong>Here is a 5 min' demo video I made of how to make casting green sand.</strong></u><br /><iframe height="315" src="http://www.youtube.com/embed/vo1vcJG4E94?rel=0" frameborder="0" width="560"></iframe>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-12733789498947670272011-09-20T11:53:00.000-07:002011-09-20T13:30:42.869-07:00Aluminum Spoon and Chicken Sand CastingIn this post I will show two castings that I made in one <a href="http://www.flamingfurnace.com/2011/02/sand-casting-terminology.html">flask</a>. I used two of my children's toys: a spoon and a toy chicken so I could engrave them as souvenir for them for years from now. I started by making the impression in the sand, I think I mentioned it before but the easiest type of pattern to duplicate for sand mould is a flat pattern. All that is needed is a bit of patience when digging out the <a href="http://www.flamingfurnace.com/2011/02/sand-casting-terminology.html">sand</a> after flipping over the <a href="http://www.flamingfurnace.com/2011/02/sand-casting-terminology.html">drag</a> part. It is important to carve around the pattern as far is its parting line to prevent breaking the sand when lifting the pattern out of the <a href="http://www.flamingfurnace.com/2011/02/sand-casting-terminology.html">sand.<br /><span style="font-size:0;"></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnZHaeLTIpibArfCGAfDsgoV3WH1SqzmaliAWF89wNur_rw2ge_S38ZaJhs0LKxQ-3VL_pBHWaJYMUQfRYjY-1sj6aB1hG6wPTGYrAkfLU_bNnVRTAXYLRjXZE3-NWUH25a9svkAQlrPrs/s1600/DSCF0157+%2528Small%2529.JPG"><img style="WIDTH: 149px; HEIGHT: 98px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654537340340803938" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnZHaeLTIpibArfCGAfDsgoV3WH1SqzmaliAWF89wNur_rw2ge_S38ZaJhs0LKxQ-3VL_pBHWaJYMUQfRYjY-1sj6aB1hG6wPTGYrAkfLU_bNnVRTAXYLRjXZE3-NWUH25a9svkAQlrPrs/s200/DSCF0157+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUbKFssOcUBI3GevTnfAoyUcLEhVJMMAh9RwIrMKBDy_VJsWNMP8POCsvZr-83qxKzDe-I3CBQAf52uoxslQqV1WrvCo-5ESfg-kCgcIiKwa05CtDhAK7cvulgYqzRBuwrWVVpi_7bcgD0/s1600/DSCF0159+%2528Small%2529.JPG"><img style="WIDTH: 152px; HEIGHT: 96px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654518881261903218" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUbKFssOcUBI3GevTnfAoyUcLEhVJMMAh9RwIrMKBDy_VJsWNMP8POCsvZr-83qxKzDe-I3CBQAf52uoxslQqV1WrvCo-5ESfg-kCgcIiKwa05CtDhAK7cvulgYqzRBuwrWVVpi_7bcgD0/s200/DSCF0159+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitSg9TKQRyc59GGk2bL3UAhpPR0UC12YTAfNMYajtmos2hz5jw0k7baIGFCEiU-D61A8osBhV0MJZv9N8TUgoSUa3deyZREbJw5Tfiu8fb5aqu_ga2J0dji17fiVD4iNbP3Kp2Pr63JXYs/s1600/DSCF0163+%2528Small%2529.JPG"><img style="WIDTH: 145px; HEIGHT: 95px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654518884313125858" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitSg9TKQRyc59GGk2bL3UAhpPR0UC12YTAfNMYajtmos2hz5jw0k7baIGFCEiU-D61A8osBhV0MJZv9N8TUgoSUa3deyZREbJw5Tfiu8fb5aqu_ga2J0dji17fiVD4iNbP3Kp2Pr63JXYs/s200/DSCF0163+%2528Small%2529.JPG" /></a><br />As I did mention before it is good practice to pre-heat any ingots or scrap aluminum before throwing it into the <a href="http://www.flamingfurnace.com/p/foundry-terminology.html">crucible</a> molten aluminum. Two reasons, one: cold metal will "freeze" the molten metal in the crucible and second: to eliminate moisture coming in contact with molten metal if ingots where left in the wet. You can see in my foundry I used mesh on the top of the lid hole that works perfect for me. Very important to work safe with foundry gloves and pliers when lifting and placing hot ingots into the crucible and also face shield protection.<br />In one of my visits down the beach I found a pressure cooker lid washed ashore so that happily got a new "life" in my <a href="http://www.flamingfurnace.com/p/foundry-terminology.html">crucible</a> and I also melted my sons broken scooter ;-)<br />The last image is scrap aluminum from my old electric router and sander. What ever scrap is to big to fit into my <a href="http://www.flamingfurnace.com/p/foundry-terminology.html">crucible</a> it ends up chopped up or broken with a heavy hammer but they all end up as nice <a href="http://www.flamingfurnace.com/2011/01/aluminum-ingots-for-foundry.html">ingots</a> ready to become a new object.....<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpfavQEI6JCbq-KA6tMWAIa_1qi18APMAcp8QVEeL4x0E6JbKPpnD6PMnAWb1hxb-FN4FI4LK9TZ0moQk_R2hYD-a7SWrc0BoBNmHLOEQ5OPKcLOdM7KqXp6yNQPL2fqdODMzh72LSUQPd/s1600/pre-heating+foundry+ingots.JPG"><img style="WIDTH: 100px; HEIGHT: 75px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654522482061940834" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpfavQEI6JCbq-KA6tMWAIa_1qi18APMAcp8QVEeL4x0E6JbKPpnD6PMnAWb1hxb-FN4FI4LK9TZ0moQk_R2hYD-a7SWrc0BoBNmHLOEQ5OPKcLOdM7KqXp6yNQPL2fqdODMzh72LSUQPd/s200/pre-heating+foundry+ingots.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_HrNEUsIsLO_c8lOvUE7NlEiQgv6f5Vmcax4IXSPLl0moooXnJp_v7FnRwxWGpT0HN2oFSaOyPW1ZYP1ix2bC1n2yt-Knn6D-0Ud2APqk-fGedV6rnbcw3rj70rTjUYSvcGlCOaJ6VF-r/s1600/aluminum+preshure+pot+lid.JPG"><img style="WIDTH: 115px; HEIGHT: 73px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654522448786122866" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_HrNEUsIsLO_c8lOvUE7NlEiQgv6f5Vmcax4IXSPLl0moooXnJp_v7FnRwxWGpT0HN2oFSaOyPW1ZYP1ix2bC1n2yt-Knn6D-0Ud2APqk-fGedV6rnbcw3rj70rTjUYSvcGlCOaJ6VF-r/s200/aluminum+preshure+pot+lid.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje16evUhgPKTCivjMfurmZSFZWHgkTY3HV5fjwQWy9_Nrpvbh6lJUU1YBLxIk9UQJOhtfnHRmy_mAXcYgBGi1KPCmeoJFwUepqqj8kk9y9WwD9iGfhyphenhyphen_zCn4bo9ypfSMr2xr0roADCGYaH/s1600/aluminum+scooter.JPG"><img style="WIDTH: 106px; HEIGHT: 73px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654522483854619714" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje16evUhgPKTCivjMfurmZSFZWHgkTY3HV5fjwQWy9_Nrpvbh6lJUU1YBLxIk9UQJOhtfnHRmy_mAXcYgBGi1KPCmeoJFwUepqqj8kk9y9WwD9iGfhyphenhyphen_zCn4bo9ypfSMr2xr0roADCGYaH/s200/aluminum+scooter.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhL8ERSkcke31UFeXN_g2J0wCGCGPVC1dk6VZTNl6v1b5hZK1aOrl562LJ6aRWs-aAaJKhZBSG2pi9f73HCF1Zj17Ig9UtDXyk-0p3PD_Sy7Bb9n7TQuqdJ3yd7RvFIVHRGCVXWSbXyV46p/s1600/scrap+aluminum+to+melt.JPG"><img style="WIDTH: 112px; HEIGHT: 70px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654522486724390338" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhL8ERSkcke31UFeXN_g2J0wCGCGPVC1dk6VZTNl6v1b5hZK1aOrl562LJ6aRWs-aAaJKhZBSG2pi9f73HCF1Zj17Ig9UtDXyk-0p3PD_Sy7Bb9n7TQuqdJ3yd7RvFIVHRGCVXWSbXyV46p/s200/scrap+aluminum+to+melt.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpdTQyJUMMHRuM9vjOd3MKwIlObXU3TTnhhvfKQemFTL-lL6OtA1r9SvkcTXcEsnE-oXVmBd5pYSoqx0JFAd2DP4384Z8RpVaIfNRiT17VNHDeTy-_8fVq7-JvEYt718Jyh8hylPd4Mgtz/s1600/aluminum+p.c.l.JPG"><img style="WIDTH: 112px; HEIGHT: 71px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654541402202297106" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpdTQyJUMMHRuM9vjOd3MKwIlObXU3TTnhhvfKQemFTL-lL6OtA1r9SvkcTXcEsnE-oXVmBd5pYSoqx0JFAd2DP4384Z8RpVaIfNRiT17VNHDeTy-_8fVq7-JvEYt718Jyh8hylPd4Mgtz/s200/aluminum+p.c.l.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHJGDUzcqkbyUmJsPf4aJN0vaeTUekZKeO1D1tQu3TFSInpuA-fX5oQmk8xxstFMnSQZnoDH5tVOBt6gm6Ec4wFOsy-sZH7dBuYaaiYOiG95drhmwfLbULxOFY-AMi2ephTjUnH3jrHxOz/s1600/aluminum+scooter+2.JPG"><img style="WIDTH: 101px; HEIGHT: 71px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654541406350175458" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHJGDUzcqkbyUmJsPf4aJN0vaeTUekZKeO1D1tQu3TFSInpuA-fX5oQmk8xxstFMnSQZnoDH5tVOBt6gm6Ec4wFOsy-sZH7dBuYaaiYOiG95drhmwfLbULxOFY-AMi2ephTjUnH3jrHxOz/s200/aluminum+scooter+2.JPG" /></a><br />In the next images you can see the aluminum spoon and chicken turned out very well and all the left over aluminum turned back into <a href="http://www.flamingfurnace.com/2011/01/aluminum-ingots-for-foundry.html">ingots</a>.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0nCVFCdADnHFelKc0gg0ARFZZSheqmXQ3_Dnhxrzcutab0D3DVFqVV2AuuvQ46tfDbYBfMA4cZoF-j6YtOJg-FnxpNaz1hcrCatqbZ885prXzgY1tfk0L_0-GX5QLUSN8Pa3wZ7RHGsA3/s1600/DSCF0181+%2528Small%2529.JPG"><img style="WIDTH: 111px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654524749011589170" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0nCVFCdADnHFelKc0gg0ARFZZSheqmXQ3_Dnhxrzcutab0D3DVFqVV2AuuvQ46tfDbYBfMA4cZoF-j6YtOJg-FnxpNaz1hcrCatqbZ885prXzgY1tfk0L_0-GX5QLUSN8Pa3wZ7RHGsA3/s200/DSCF0181+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJ0cUxFJLA59Y5bsqz38sin0JyQA1OoRcw5sqagVefrL__K0YGHtT8gK_jeY5XFbPjcwTahNw5vBolxIAMY4V16EjEH-WYPujC7NU1OUJhEj8bPBad23RI_61Af2SII9G7hur_Nmq3wqEr/s1600/DSCF0187+%2528Small%2529.JPG"><img style="WIDTH: 112px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654524751344028338" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJ0cUxFJLA59Y5bsqz38sin0JyQA1OoRcw5sqagVefrL__K0YGHtT8gK_jeY5XFbPjcwTahNw5vBolxIAMY4V16EjEH-WYPujC7NU1OUJhEj8bPBad23RI_61Af2SII9G7hur_Nmq3wqEr/s200/DSCF0187+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0nnhmjKw5wtMoMv1Ym3fpT9MZkZOdtU1Yxc7byqPLIUrzFR9kxXJrinfbTZ-kWxuVDgUXTywOBvBbrlzV5_OiyF7iwSuTaSXWAiZjYm2UxEAODex-8i0RUNTKW7mX4B63TOMpWtQuGkMk/s1600/DSCF0198+%2528Small%2529.JPG"><img style="WIDTH: 116px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654524750090319922" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0nnhmjKw5wtMoMv1Ym3fpT9MZkZOdtU1Yxc7byqPLIUrzFR9kxXJrinfbTZ-kWxuVDgUXTywOBvBbrlzV5_OiyF7iwSuTaSXWAiZjYm2UxEAODex-8i0RUNTKW7mX4B63TOMpWtQuGkMk/s200/DSCF0198+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaGIxtWbYH8LSJ_rnTLdAUltd2wnPt9P8fEORvIVqKd22cN3Dqsb64p5GRxej3p9N_EwRKK3PH0ziCIOAgDC4OZVXTTWsGFz1ZiuyMUikl5d8mqZ5NR6MkuuyJ5x1DI_SAjCo2S_Tm1FTl/s1600/DSCF0205+%2528Small%2529.JPG"><img style="WIDTH: 129px; HEIGHT: 83px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654524754135690578" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaGIxtWbYH8LSJ_rnTLdAUltd2wnPt9P8fEORvIVqKd22cN3Dqsb64p5GRxej3p9N_EwRKK3PH0ziCIOAgDC4OZVXTTWsGFz1ZiuyMUikl5d8mqZ5NR6MkuuyJ5x1DI_SAjCo2S_Tm1FTl/s200/DSCF0205+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6kZQVsXGAlnlo641qzk-WF25C9TfKEHM4uMh0leQBb928dH18KvaL5OHFNK2iYfXv4N0Md4DTZzqbzixSUGarUl9XuBtrMPucay84z7eQHxdoTCkLabnfQGZxzKO_Eq_ZmE3e_XimwQ7n/s1600/DSCF0212+%2528Small%2529.JPG"><img style="WIDTH: 121px; HEIGHT: 81px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654524759575388882" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6kZQVsXGAlnlo641qzk-WF25C9TfKEHM4uMh0leQBb928dH18KvaL5OHFNK2iYfXv4N0Md4DTZzqbzixSUGarUl9XuBtrMPucay84z7eQHxdoTCkLabnfQGZxzKO_Eq_ZmE3e_XimwQ7n/s200/DSCF0212+%2528Small%2529.JPG" /></a><br />The <a href="http://www.flamingfurnace.com/2011/02/sand-casting-terminology.html">sprue and riser </a>did their job and you can see in the image that the casting was "feeding" from it while it was in the solidifying stage. After cutting off the <a href="http://www.flamingfurnace.com/2011/02/sand-casting-terminology.html">sprue and riser </a>I gave the casting a bit of cleaning with a metal file. Then some light sanding and polishing on the buffing wheel.<br />Now its ready for custom engraving.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTvXfJpsTanWxSbW1zg0zTR7gt3OZliv7tfR2m3CmijTH47dT8qoxRClXsLtbTQ3VvnZR588HngC_KYv69UW0mHBm__Zvttpygi7p3JrHb5PndmAON6yCeMHPAdjm4Wswr7oFFKcInV0U6/s1600/aluminum+spoon+and+chicken+with+sprue+and+riser.JPG"><img style="WIDTH: 90px; HEIGHT: 97px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654526451975539282" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTvXfJpsTanWxSbW1zg0zTR7gt3OZliv7tfR2m3CmijTH47dT8qoxRClXsLtbTQ3VvnZR588HngC_KYv69UW0mHBm__Zvttpygi7p3JrHb5PndmAON6yCeMHPAdjm4Wswr7oFFKcInV0U6/s200/aluminum+spoon+and+chicken+with+sprue+and+riser.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhI31lfifQupPwVFMvb_cKPG2YndQY6puaXDDU9sjxDS-siLGHR6ha8aZrjfbYCp8UMUEEj-7971SxXAAqLxyiLdbNDPTh-lkpOXROEivUWaHOeUJmFhlUAcDsAzyXWsO3bswqHtg-O7J2J/s1600/DSCF0233+%2528Small%2529.JPG"><img style="WIDTH: 121px; HEIGHT: 87px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654526443845597154" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhI31lfifQupPwVFMvb_cKPG2YndQY6puaXDDU9sjxDS-siLGHR6ha8aZrjfbYCp8UMUEEj-7971SxXAAqLxyiLdbNDPTh-lkpOXROEivUWaHOeUJmFhlUAcDsAzyXWsO3bswqHtg-O7J2J/s200/DSCF0233+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEid4F6xHM737DITjnEJym3rmGKohElrIq8RWUo_Ny5Qrf0S_-KHnNr4eVZL_xB0Uh-bUNueP3ZiqOf_06N8RZmFjwOUxC-ewa7wPN75S-rQIOXgcnAg7Sv_6AsMukZana_7ELsrxON9eC24/s1600/DSCF0255+%2528Small%2529.JPG"><img style="WIDTH: 120px; HEIGHT: 86px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654527384497144626" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEid4F6xHM737DITjnEJym3rmGKohElrIq8RWUo_Ny5Qrf0S_-KHnNr4eVZL_xB0Uh-bUNueP3ZiqOf_06N8RZmFjwOUxC-ewa7wPN75S-rQIOXgcnAg7Sv_6AsMukZana_7ELsrxON9eC24/s200/DSCF0255+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje64MOEwtvBDJh-ug49vm3dbSR610z6mVkoIc0gIt0lk6ehki4BFqQmS4N3lLqJbTQhaCiudRus2KKLChYdrvUmEPXxpxvUXuiOWBTWpje9CRIalhlQvNPuWQBua1hnX9HdjxywGzADLqx/s1600/aluminum+spoon+sand+casting.JPG"><img style="WIDTH: 119px; HEIGHT: 84px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654526448831759186" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje64MOEwtvBDJh-ug49vm3dbSR610z6mVkoIc0gIt0lk6ehki4BFqQmS4N3lLqJbTQhaCiudRus2KKLChYdrvUmEPXxpxvUXuiOWBTWpje9CRIalhlQvNPuWQBua1hnX9HdjxywGzADLqx/s200/aluminum+spoon+sand+casting.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWtb7_sOuuSvTxlkwhXi6TdvpEviZC4_4wgG8KEwmQCq3YvlZ7OwWKZCZ1-PJ3hQDUGk-HDl1xICpFiFsC-IxUyg7tTTZYDrn9Jd8pUI-nWqfI2p9wBcdj8cD3A8VFNagpQT1mOKbbp3PI/s1600/aluminum+spoon+and+chicken+sand+casting.JPG"><img style="WIDTH: 147px; HEIGHT: 92px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5654526443662437154" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWtb7_sOuuSvTxlkwhXi6TdvpEviZC4_4wgG8KEwmQCq3YvlZ7OwWKZCZ1-PJ3hQDUGk-HDl1xICpFiFsC-IxUyg7tTTZYDrn9Jd8pUI-nWqfI2p9wBcdj8cD3A8VFNagpQT1mOKbbp3PI/s200/aluminum+spoon+and+chicken+sand+casting.JPG" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-87977700362292516082011-08-12T13:03:00.000-07:002013-01-04T11:54:37.071-08:00Oil Bonded Sand, Molding Aluminum SunIts been 3 months since my last post so I am back now with a few new aluminum castings and more tips and images. In this post I am showing my casting of an aluminum sun. <a href="http://www.flamingfurnace.com/2011/02/aluminum-sun-sand-casting.html">This is a link to my first aluminum sun casting.</a> The pattern I used for this casting was a clay sun that I varnished so it would be easier to remove it from the sand mould and to achieve a good finishing. For this large casting I made a new timber flask as you can see in the images. The <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">flask </a>dimentions are 390mm x 390mm x 80mm. <span style="color: #000099;">Because it's a large flask this is a good tip to keep in mind: when working with such a big flask it is good practice to create inner "ribs" for the flask or just to make a few grooves with an electric router, any way is good.</span> It is very annoying when you work hard on your sand moulding and just as you are about to place the <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">cope</a> on top of the <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">drag</a> all the sand falls out.
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUq3B2a6wStTdtHuLYeW3x67fsLBxltCP_Toy9rI7M248eR8LCbELkzRs3Lt3V4EjQJ7ckmUeT0nuU470ZkoNynKP8jntTwdssx0k81eicrv49qfp4qXLUhnLLfgvm6n6LxVAQPyV0s3Fo/s1600/DSCF9688+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641556631540125378" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUq3B2a6wStTdtHuLYeW3x67fsLBxltCP_Toy9rI7M248eR8LCbELkzRs3Lt3V4EjQJ7ckmUeT0nuU470ZkoNynKP8jntTwdssx0k81eicrv49qfp4qXLUhnLLfgvm6n6LxVAQPyV0s3Fo/s200/DSCF9688+%2528Small%2529.JPG" style="cursor: hand; height: 108px; width: 162px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPqsNGACcxOfYeop2fb8we5Lc9PngNWozfuRECP5j0lNeMoDjuFN0a2RrmRaDgPVm3CxxtlLf7NhSAqh2ngP1ZfI3MQ-t_tqG6gH7eTqu64aQh5xBSzdpuu4fq7fJDJ7zRqsced19EO4kf/s1600/DSCF9684+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641556627771121346" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPqsNGACcxOfYeop2fb8we5Lc9PngNWozfuRECP5j0lNeMoDjuFN0a2RrmRaDgPVm3CxxtlLf7NhSAqh2ngP1ZfI3MQ-t_tqG6gH7eTqu64aQh5xBSzdpuu4fq7fJDJ7zRqsced19EO4kf/s200/DSCF9684+%2528Small%2529.JPG" style="cursor: hand; height: 106px; width: 149px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyusJqq3DRcWxev3iUFz3qsAHmpjzB5XxfyaW5nPeE2UTTultp13RPKFTgq1-5HTxBLWjl0fKgWH-6mDf4-ySm-_T7uoXzwbfEnSgI8sCgEXn2nIoGYk3eh_tWw3362z7HZarF2WHwgBon/s1600/DSCF9896+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641559738661446018" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyusJqq3DRcWxev3iUFz3qsAHmpjzB5XxfyaW5nPeE2UTTultp13RPKFTgq1-5HTxBLWjl0fKgWH-6mDf4-ySm-_T7uoXzwbfEnSgI8sCgEXn2nIoGYk3eh_tWw3362z7HZarF2WHwgBon/s200/DSCF9896+%2528Small%2529.JPG" style="cursor: hand; height: 104px; width: 137px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2618aTfaWlt-VK5ndczxW5N07c-mNh8oFUistwiWOzmLVyh1yJHAkBD7ni6OS3-hMk0lSysbZCWsnRpRC4vwXY9l__PuBXFExk5RUDy9EbvxEaNQrasIoZv6Qf0z7dNdWFn7B1uH2NAIr/s1600/DSCF9891+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641559744505508514" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2618aTfaWlt-VK5ndczxW5N07c-mNh8oFUistwiWOzmLVyh1yJHAkBD7ni6OS3-hMk0lSysbZCWsnRpRC4vwXY9l__PuBXFExk5RUDy9EbvxEaNQrasIoZv6Qf0z7dNdWFn7B1uH2NAIr/s200/DSCF9891+%2528Small%2529.JPG" style="cursor: hand; height: 100px; width: 148px;" /></a>
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The sand moulding was very easy to make and I was able to lift the sun pattern without damaging the sun impression in the sand. The inner ribs also worked very well and the <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">petrobond</a> didn't fall out of the <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">flask</a>. I also got another bag of petrobond and in the images you can see the differance in the color. After many uses petrobond turns dark brown vs orange color for new petrobond.
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEsIZBkz8veG2Q6GhGMqebrksoWVQoidWDvM-FDl9KXexhZ7cXOsx1k8f80K8wDwGXWDrY3lURZNqECb8F-UPSk9T_snTpc_PKtj_UbX6BsCSEd-8d6500IFFWQWEKE4QTrX4uIG8tiSD5/s1600/DSCF9874+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641558547963718818" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEsIZBkz8veG2Q6GhGMqebrksoWVQoidWDvM-FDl9KXexhZ7cXOsx1k8f80K8wDwGXWDrY3lURZNqECb8F-UPSk9T_snTpc_PKtj_UbX6BsCSEd-8d6500IFFWQWEKE4QTrX4uIG8tiSD5/s200/DSCF9874+%2528Small%2529.JPG" style="cursor: hand; height: 77px; width: 108px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEir2PnW9vORYQVAZhE0jbtH_ZeBb8gl3Mo-sv6htjCN0VDOoprQs7zwvXKYeK-WCIqgCGnJ9yYn1nonaBwUGqVghNST3y2_Ikiftber09r4Qksyq66iytN2p8knRLFzyEcVwcvjVft63Jcj/s1600/DSCF9875%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641558552469693490" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEir2PnW9vORYQVAZhE0jbtH_ZeBb8gl3Mo-sv6htjCN0VDOoprQs7zwvXKYeK-WCIqgCGnJ9yYn1nonaBwUGqVghNST3y2_Ikiftber09r4Qksyq66iytN2p8knRLFzyEcVwcvjVft63Jcj/s200/DSCF9875%2528Small%2529.JPG" style="cursor: hand; height: 75px; width: 113px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUwDxWX9sU_y8wdPYdEZ4W4GN5z8nqZ0OfwLF87d6mxNd1uwNlJToEU-8Ywds5CuAwPtm8wVFZ6ZsvExQQpb9XfWQealzXLc4Cx_DrYJg8hH4ijwJ6oI6M7iQ19bc_4bUPyoTNcyeOcGce/s1600/DSCF9878+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641558553569769602" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUwDxWX9sU_y8wdPYdEZ4W4GN5z8nqZ0OfwLF87d6mxNd1uwNlJToEU-8Ywds5CuAwPtm8wVFZ6ZsvExQQpb9XfWQealzXLc4Cx_DrYJg8hH4ijwJ6oI6M7iQ19bc_4bUPyoTNcyeOcGce/s200/DSCF9878+%2528Small%2529.JPG" style="cursor: hand; height: 73px; width: 120px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhX3AfVsOWd8XsRzoX7a6M1dKo-Oowt8bO8scuSRgDscczBljJw_vUDUlCNY7Z3k4SYa9GwoLYyNv9vZUdX4xXalH-L26wQl5v0M_AOVupA3x-z9dfRoJUAmEUhRdU4TQSZGi7no-_gM1Ip/s1600/DSCF9881+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641559734654742562" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhX3AfVsOWd8XsRzoX7a6M1dKo-Oowt8bO8scuSRgDscczBljJw_vUDUlCNY7Z3k4SYa9GwoLYyNv9vZUdX4xXalH-L26wQl5v0M_AOVupA3x-z9dfRoJUAmEUhRdU4TQSZGi7no-_gM1Ip/s200/DSCF9881+%2528Small%2529.JPG" style="cursor: hand; height: 75px; width: 117px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi_P0QmtTEz_rCaFRZdXXB_lp8Ak_HxwiY3O6cowWKvnKmu2GiTOMzXdRHTGH9vFyN35mKegAl1GNJ-nbpBCvDOqNidZzeB16vejgBVWN_eRSF-ZhYPWqPWHDSn198IkucFQpw5bzRsmvD/s1600/DSCF9882%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641559740545070930" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi_P0QmtTEz_rCaFRZdXXB_lp8Ak_HxwiY3O6cowWKvnKmu2GiTOMzXdRHTGH9vFyN35mKegAl1GNJ-nbpBCvDOqNidZzeB16vejgBVWN_eRSF-ZhYPWqPWHDSn198IkucFQpw5bzRsmvD/s200/DSCF9882%2528Small%2529.JPG" style="cursor: hand; height: 76px; width: 111px;" /></a>
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My first sand mould was perfect but when I was finishing it I got distracted and forgot a very important thing, I didn't place my clamps on the flask. <span style="color: #000099;">Here is a very important tip: The clamps or just a weight on top of the flask will prevents the molten metal from lifting the cope part (Hydrostatic pressure) and resulting in a pool of molten metal on the floor also burning the flask if it's constructed from timber. This causes a casting defect called FLASH (see flash image circled in red)</span>.
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I made a lot of castings till this day and never forgot the clamps, so this can easily happen and can be very dangerous if you don't keep safety in mind. Because I always cast in the open on dry sand no harm was done. The only annoying part was to cut off, file and grind the casting FLASH. *** In the future I will post info explaining in more detail the most common casting defects***
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmSVh74avojdp-ZPmKyIImimlCNyZrptUZBo-URqPv5aELqULpxXVqp0QWqko6g-KmuVGlz9-2rItlQmxDtGVrAV3WPM6B3MHvWQzwSaxBQ4zampsyafPpLX25930B5-fWhK7L3mcM4Bod/s1600/DSCF0046+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641564222182775074" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmSVh74avojdp-ZPmKyIImimlCNyZrptUZBo-URqPv5aELqULpxXVqp0QWqko6g-KmuVGlz9-2rItlQmxDtGVrAV3WPM6B3MHvWQzwSaxBQ4zampsyafPpLX25930B5-fWhK7L3mcM4Bod/s200/DSCF0046+%2528Small%2529.JPG" style="cursor: hand; height: 97px; width: 170px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhNq2shD91ISWtHBX04KzM5wgOqA0j2mf0rhNxw_ChVU58YMdOMAeW0JerOn2XSGaOUqKkfeaGe0dBd_8Tj3NsFLHTEUI3CKdF3C44qa1-0pEwIp2j_VJ4IOhPLAvNhWV0YiXnGauOosmM/s1600/DSCF9916+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641564220330592802" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhNq2shD91ISWtHBX04KzM5wgOqA0j2mf0rhNxw_ChVU58YMdOMAeW0JerOn2XSGaOUqKkfeaGe0dBd_8Tj3NsFLHTEUI3CKdF3C44qa1-0pEwIp2j_VJ4IOhPLAvNhWV0YiXnGauOosmM/s200/DSCF9916+%2528Small%2529.JPG" style="cursor: hand; height: 97px; width: 156px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6iYzKHYiTbMyEiAiwBdIgt3IQeEDk5MYlBRwOtIxTJd25Ne_zBlayPgFq-tLAtlr4ACqrDV3pxrCkt1MceLDuQGvzSmD3zdvS5c2mt3JbySq1d64Ry44u6YHjHKpWZVBWJtKIsl2QYQST/s1600/DSCF0055+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641564227106702178" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6iYzKHYiTbMyEiAiwBdIgt3IQeEDk5MYlBRwOtIxTJd25Ne_zBlayPgFq-tLAtlr4ACqrDV3pxrCkt1MceLDuQGvzSmD3zdvS5c2mt3JbySq1d64Ry44u6YHjHKpWZVBWJtKIsl2QYQST/s200/DSCF0055+%2528Small%2529.JPG" style="cursor: hand; height: 99px; width: 141px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYZALnFez0T4Drn61W1RR671CDHzLQfhKp6375ZSg5LGQpAwOuvm-mUSGwZqCDnmuZsTDFWGwKxfRGXgm-hjcxlAJzksXaHI3MrK5Oq9ZWIlfGE0uJwNNTqgUnQVGV7Vzhu4bbyEfgivP5/s1600/melting+aluminum+ingots+%2528Large%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641564234676289298" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYZALnFez0T4Drn61W1RR671CDHzLQfhKp6375ZSg5LGQpAwOuvm-mUSGwZqCDnmuZsTDFWGwKxfRGXgm-hjcxlAJzksXaHI3MrK5Oq9ZWIlfGE0uJwNNTqgUnQVGV7Vzhu4bbyEfgivP5/s200/melting+aluminum+ingots+%2528Large%2529.JPG" style="cursor: hand; height: 102px; width: 131px;" /></a>
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My second casting was very sucessful, I didnt forget the clamps this time... :-)
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrrrN7N5n2vekTbSpvdVLNccJRv-WBAmVRKMJqVKqDY6tXb9nS4lFbyZte6t6OQ49N42AumAEjq2s6tkb8hDq-SE23loz2FuJbiIS5Ybz1rA6T3uxLuWmIZ98Tt2zmsOJx0SdWEdrQzijS/s1600/DSCF0076+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641566262606949250" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrrrN7N5n2vekTbSpvdVLNccJRv-WBAmVRKMJqVKqDY6tXb9nS4lFbyZte6t6OQ49N42AumAEjq2s6tkb8hDq-SE23loz2FuJbiIS5Ybz1rA6T3uxLuWmIZ98Tt2zmsOJx0SdWEdrQzijS/s200/DSCF0076+%2528Small%2529.JPG" style="cursor: hand; height: 105px; width: 154px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8XT8YtPOv6LVHUfeI-6LBs3MBWB8Rm_Gn-k-7I4mjbDPm2n64Jaqa0EOKGxgpX4mL0bCRvwlFBvgWNKWo87-kgDx5hVH8Vc29nQ_8xdZws2XwFCdmafkKtJgN0thQyAOu4Ccm7ymgUeRF/s1600/DSCF0081+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641566264570986082" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8XT8YtPOv6LVHUfeI-6LBs3MBWB8Rm_Gn-k-7I4mjbDPm2n64Jaqa0EOKGxgpX4mL0bCRvwlFBvgWNKWo87-kgDx5hVH8Vc29nQ_8xdZws2XwFCdmafkKtJgN0thQyAOu4Ccm7ymgUeRF/s200/DSCF0081+%2528Small%2529.JPG" style="cursor: hand; height: 102px; width: 151px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhewJSDF7EqNvHdwMivT6_8CHak9h8pcIBgSNkohS15BYXf1HiHlQBEEsFaM2cOfryIz_0DniLmz95r6U8qZXkmJ8b_R-B3qTaErVJjvjI-33AqfF_eJxGBFkywBZI6cvXtSMwfhovB_fA/s1600/DSCF0087+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641566270142592514" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhewJSDF7EqNvHdwMivT6_8CHak9h8pcIBgSNkohS15BYXf1HiHlQBEEsFaM2cOfryIz_0DniLmz95r6U8qZXkmJ8b_R-B3qTaErVJjvjI-33AqfF_eJxGBFkywBZI6cvXtSMwfhovB_fA/s200/DSCF0087+%2528Small%2529.JPG" style="cursor: hand; height: 104px; width: 148px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieF1eZbMjK5JCXbpHX3_0gbL3aUQjl_QCT4HDqRt7HSMPLieNv3oQ8udly-cctmIW_RTfQnuvmDibZkXJeRTdKJqWpU5TJURfQXhBjIHP5_mT4NWmzyzoybETOIfYb-mELorNDD-JO_N1r/s1600/DSCF0072+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641566256480147810" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieF1eZbMjK5JCXbpHX3_0gbL3aUQjl_QCT4HDqRt7HSMPLieNv3oQ8udly-cctmIW_RTfQnuvmDibZkXJeRTdKJqWpU5TJURfQXhBjIHP5_mT4NWmzyzoybETOIfYb-mELorNDD-JO_N1r/s200/DSCF0072+%2528Small%2529.JPG" style="cursor: hand; height: 102px; width: 154px;" /></a>
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On the top image 3rd from the left you can see the two sun castings. On the left is the sun from my first casting after cleaning the flash defects and giving it a bit of a polish and the right sun is the second casting which turned out to be a very good quality casting with zero defects. I drilled two holes in the sun and attached it on my garden wall with my <a href="http://www.flamingfurnace.com/2011/03/aluminum-eagle-sand-casting.html">eagle castings</a>.
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiiYXXaOfVywrYEJSfG99t4rFrqYO4qYNDmXpm18e-d2wOJapfPdCh72cIi8fIbBz5qthtY5IS-Y6qMiClYQWLFOaSWrgUwvlYz77qKonr6zqnSWk9jAkhTS2xqynieIRJ_bVZrx-HKyR5y/s1600/DSCF0133+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641566274238058882" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiiYXXaOfVywrYEJSfG99t4rFrqYO4qYNDmXpm18e-d2wOJapfPdCh72cIi8fIbBz5qthtY5IS-Y6qMiClYQWLFOaSWrgUwvlYz77qKonr6zqnSWk9jAkhTS2xqynieIRJ_bVZrx-HKyR5y/s200/DSCF0133+%2528Small%2529.JPG" style="cursor: hand; height: 107px; width: 155px;" /></a>
FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-9174555234387560272011-05-17T11:40:00.000-07:002013-02-22T08:50:49.246-08:00Sand Casting Ray Phaser, Solid AluminumIn this aluminum casting I made a replica of two different water guns. The problem that I had here was that if I tried to open the plastic casting of the water gun I would probably break it. Casting a two half pattern is a very easy process and the finishing is better then using a one piece pattern. My decision was to try creating the sand mould using the gun as one part. The only difference in using a full part is it's more time consuming by carving the sand around pattern half way without braking the sand mould.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbfFy6RD-A1jteAs9sY25IAAzuc8dH7COgnLakwFAQgoSGmsJCcYGf_j4bka1cmghVQBLYDw3sVK7isct0tfO8qQst9TZrVjAnj-JZbbqwAwPI6f8WuMoeKJy_JFFJ9Ysp1WsbEuVRON-S/s1600/aluminum+ray+gun+sand+casting.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607758600270817970" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbfFy6RD-A1jteAs9sY25IAAzuc8dH7COgnLakwFAQgoSGmsJCcYGf_j4bka1cmghVQBLYDw3sVK7isct0tfO8qQst9TZrVjAnj-JZbbqwAwPI6f8WuMoeKJy_JFFJ9Ysp1WsbEuVRON-S/s200/aluminum+ray+gun+sand+casting.JPG" style="cursor: hand; height: 89px; width: 146px;" /></a><br />
Making the pattern without breaking the mould worked well.<br />
<span style="color: #000099;">This is another <u>tip</u> how to locate the point of <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">sprue and riser </a>in the <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">cope part</a>. There are a few methods such as marking the sand or just measuring the center point. I used two small aluminum tubes placing them into the sprue and riser well and then carefully placing the cope part on top only to create the mark on the cope for the sprue and riser.</span><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWCH1_-TCNF5gVZSzjw7TsR-0qjKv1r2UlAbmmBFfnw6CprGfKX9EOUAyMnZXIz3rswSKe_MrAIl43YWLMb8uwdnGwFkJLvZs3ZFv1haEWo0Lr7tDUYXzYioFVqq22mwqDMnQu_2KRIV2p/s1600/raygun1.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607760441445021090" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWCH1_-TCNF5gVZSzjw7TsR-0qjKv1r2UlAbmmBFfnw6CprGfKX9EOUAyMnZXIz3rswSKe_MrAIl43YWLMb8uwdnGwFkJLvZs3ZFv1haEWo0Lr7tDUYXzYioFVqq22mwqDMnQu_2KRIV2p/s200/raygun1.jpg" style="cursor: hand; height: 90px; width: 133px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_tZAsq_vcrD_dcSKbIlurI3rYnUJDewGGKW3-grKQ9_tE-qDLs0EOLoSFwmzNnK8aX2JH8okkN2xgwNK9N_jYvEOR_zvPu1M7EOAuU2xanCjZ7wrUJglvBbVdT2VKx32nQZaSySyvNRXC/s1600/raygun2.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607760444901315282" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_tZAsq_vcrD_dcSKbIlurI3rYnUJDewGGKW3-grKQ9_tE-qDLs0EOLoSFwmzNnK8aX2JH8okkN2xgwNK9N_jYvEOR_zvPu1M7EOAuU2xanCjZ7wrUJglvBbVdT2VKx32nQZaSySyvNRXC/s200/raygun2.JPG" style="cursor: hand; height: 90px; width: 133px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-J3p-PpzLI9AoTiszzmCzK9iESNKevHrQ4YgxzR39ETOqajqtUqAoUxqzdcUCwJb7-LX9C52LfdVqjzUGdJiNRE7i4lvokgbGdgqZl2h60IDbcegmdUWrFfe5Fku7xIbXxGUc50kHNHmB/s1600/raygun3.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607760452586933586" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-J3p-PpzLI9AoTiszzmCzK9iESNKevHrQ4YgxzR39ETOqajqtUqAoUxqzdcUCwJb7-LX9C52LfdVqjzUGdJiNRE7i4lvokgbGdgqZl2h60IDbcegmdUWrFfe5Fku7xIbXxGUc50kHNHmB/s200/raygun3.JPG" style="cursor: hand; height: 89px; width: 150px;" /></a><br />
After the sand mould was ready I turned on my furnace and in 50 minutes my <a href="http://www.flamingfurnace.com/p/foundry-terminology.html">crucible</a> was full of molten aluminum alloy ready to be poured. I really wanted this casting to turn out well and it did.<br />
I opened the flask after it cooled down and there it was....my first aluminum alloy ray gun.<br />
The ray gun casting had a bit of shrinkage on one side of the handle and that is a result of the <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">runner</a> being too narrow. <span style="color: #000099;">When casting a chunky part of aluminum it is really recommended to leave a sufficient sized runner and a large sprue and riser to feed the cooling aluminum in the mould cavity. Another tip is to always use a bit extra aluminum, better to much then to little resulting in a ruined casting. </span><br />
<br />
In the image you can see the left over aluminum in both castings turned back into ingots.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglk3tnzcagBsfS5hknpPw_7lJl-i4UL9aVk-5DZfTa3OkVXlu_1lZrTukYRrl3k5qhQT9uAJDbVOQLyBmUa9VYyL1P0R3HLyYn_MwB_uDiM6ZHLUyk_nfvR8ItuePWDhj84hVyQBfz_buQ/s1600/raygun8.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607767569992600146" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglk3tnzcagBsfS5hknpPw_7lJl-i4UL9aVk-5DZfTa3OkVXlu_1lZrTukYRrl3k5qhQT9uAJDbVOQLyBmUa9VYyL1P0R3HLyYn_MwB_uDiM6ZHLUyk_nfvR8ItuePWDhj84hVyQBfz_buQ/s200/raygun8.JPG" style="cursor: hand; height: 83px; width: 130px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiE8MyZWXC-3GrzTFB-VkIwO95OEDa5ufV6Tc6UZlZdjLEf9ItBMgglfBCoPP8TRpKE9LldbYm2AI8GyNIs2J-6Dpej1JO_4SD_ePxRG-tAkOgUVjR-Ll0qOuLVID5z1TEVjMk9df9g0vMA/s1600/raygun4.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607767573725117970" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiE8MyZWXC-3GrzTFB-VkIwO95OEDa5ufV6Tc6UZlZdjLEf9ItBMgglfBCoPP8TRpKE9LldbYm2AI8GyNIs2J-6Dpej1JO_4SD_ePxRG-tAkOgUVjR-Ll0qOuLVID5z1TEVjMk9df9g0vMA/s200/raygun4.JPG" style="cursor: hand; height: 83px; width: 130px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnDvpRMg7pSfG8OGBGJzPGtfJKRCgKQXtejz9RVsK1v34hBPHTHqpLHI31VgV-shDxnaSjSqseb68ZLtdHMPIm01vNSlbc-YUYsjsCwIT1LxXfcuBvyn-3yW2MbwlFCfHvCoE94XYqUN4I/s1600/raygun5.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607767577173802562" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnDvpRMg7pSfG8OGBGJzPGtfJKRCgKQXtejz9RVsK1v34hBPHTHqpLHI31VgV-shDxnaSjSqseb68ZLtdHMPIm01vNSlbc-YUYsjsCwIT1LxXfcuBvyn-3yW2MbwlFCfHvCoE94XYqUN4I/s200/raygun5.JPG" style="cursor: hand; height: 84px; width: 129px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjubxP0Vc7JATsmEujN9A9HiBnELMJGD2MndXkXoMtF3G1FYrWnltAch3Sk5laH7fXkdq0sldCgmojJvJi8vqlEbMJAoewbA4gvu3g3t9owKBLEGiu7tQ2P_c1A0aVonWHs_THg9KnjuIvw/s1600/raygun6.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607767584409916130" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjubxP0Vc7JATsmEujN9A9HiBnELMJGD2MndXkXoMtF3G1FYrWnltAch3Sk5laH7fXkdq0sldCgmojJvJi8vqlEbMJAoewbA4gvu3g3t9owKBLEGiu7tQ2P_c1A0aVonWHs_THg9KnjuIvw/s200/raygun6.JPG" style="cursor: hand; height: 83px; width: 130px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhw73f7CkTgVekc3cwmE8Z5wdGs_VTFrHQECdWHRLOYpdpdy6X01SmNYDqyOsRJkSgkhRwA36AX79yfXBdKkK6Rc1JRHwgpbUyoRN3F9xbGXVY4uLdxoJdNEe1VQvnjTlTYgrAffWAiRWBs/s1600/raygun7.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607767588969693794" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhw73f7CkTgVekc3cwmE8Z5wdGs_VTFrHQECdWHRLOYpdpdy6X01SmNYDqyOsRJkSgkhRwA36AX79yfXBdKkK6Rc1JRHwgpbUyoRN3F9xbGXVY4uLdxoJdNEe1VQvnjTlTYgrAffWAiRWBs/s200/raygun7.JPG" style="cursor: hand; height: 88px; width: 121px;" /></a><br />
I was very happy with the first ray gun casting and I gave it a bit of a cleaning and a light polishing on the buffing wheel.<br />
<span style="color: #000099;">Another <u>tip:</u> when using a buffing wheel always wear a face shield and hold the aluminum object firmly as I recently discovered how quickly it can fly out of your hands :-)</span><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj803IGXCjvIchUUnHeWk12KWISFjCOLiOgqjdWmSsQUaMvzofVyIGn2zqn5zfKTfjO6G_UUKvi0ZRsX8CDfnv0vHNWCv6QrkCsjztZTdV-6zPZtloGFEScs_Kjryir0TiLuX1EryV5AXyg/s1600/raygun9.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607770910684427042" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj803IGXCjvIchUUnHeWk12KWISFjCOLiOgqjdWmSsQUaMvzofVyIGn2zqn5zfKTfjO6G_UUKvi0ZRsX8CDfnv0vHNWCv6QrkCsjztZTdV-6zPZtloGFEScs_Kjryir0TiLuX1EryV5AXyg/s200/raygun9.JPG" style="cursor: hand; height: 96px; width: 140px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ9rkeCMAu8bXPwZY57gHRYg84EFu84NDanP-8BXYGX3375lkpHgMr-bxnY1EqB9DlWIqCjSmnz7pfkjtYmxM5alcdGG5kgaQp82_cBlg-2mTOsPndqDGWO5QsjJL7NC1BZmL38IW5X4V1/s1600/raygun10.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607770912307462978" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ9rkeCMAu8bXPwZY57gHRYg84EFu84NDanP-8BXYGX3375lkpHgMr-bxnY1EqB9DlWIqCjSmnz7pfkjtYmxM5alcdGG5kgaQp82_cBlg-2mTOsPndqDGWO5QsjJL7NC1BZmL38IW5X4V1/s200/raygun10.JPG" style="cursor: hand; height: 96px; width: 135px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzevOqrKemjZ2heXz4_ZQIBlEoFQzdsgikK_CoA9MOR5YPaqcD9CFjnvG_hMoye__VLZD2ZqaSpddx2Z-71-LN9MtJxR0QdPR3I3SU-ChKCcDNlg84qKZS2MUCHjzjXZ9dfdZCFz7ouCRF/s1600/raygun12.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607770908058227794" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzevOqrKemjZ2heXz4_ZQIBlEoFQzdsgikK_CoA9MOR5YPaqcD9CFjnvG_hMoye__VLZD2ZqaSpddx2Z-71-LN9MtJxR0QdPR3I3SU-ChKCcDNlg84qKZS2MUCHjzjXZ9dfdZCFz7ouCRF/s200/raygun12.JPG" style="cursor: hand; height: 96px; width: 137px;" /></a><br />
The next casting I made was of a different ray gun replica. I made this sand casting quickly, something that is not good practice. I also didn't create a <a href="http://www.flamingfurnace.com/p/sand-casting-terminology.html">well and runner</a> system for the riser so the casting has a few appearance defects but no issue of shrinkage this time.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3ue7J-99Ic37AVyOd-vo-C1bVBzd14SoJyoyk2AIzkAjJPBqwro-1xqRIihfVgfGMWefVRq1dMl_RhQgwY0IiER_8EOoG_Yy0exEW4APVlEJZwsTbZDfyKjl0JsRqEX3y7shCGvivf_e7/s1600/raygun14.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607773244065355794" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3ue7J-99Ic37AVyOd-vo-C1bVBzd14SoJyoyk2AIzkAjJPBqwro-1xqRIihfVgfGMWefVRq1dMl_RhQgwY0IiER_8EOoG_Yy0exEW4APVlEJZwsTbZDfyKjl0JsRqEX3y7shCGvivf_e7/s200/raygun14.JPG" style="cursor: hand; height: 92px; width: 119px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhy9g8PagVP87LeMYbrVm74f44yesmkZ9jlwsZ6Y7OP_eqMWGjxZSumA_7OVA8HTHAhptZ0vQbGS7JF47ePBzCCZAmH3qGV98dLn6Jc-X-FVDxf6AR1sQHmEGYZIcOKe06PBaVRgyz2lKzA/s1600/raygun17.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607773261640563538" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhy9g8PagVP87LeMYbrVm74f44yesmkZ9jlwsZ6Y7OP_eqMWGjxZSumA_7OVA8HTHAhptZ0vQbGS7JF47ePBzCCZAmH3qGV98dLn6Jc-X-FVDxf6AR1sQHmEGYZIcOKe06PBaVRgyz2lKzA/s200/raygun17.JPG" style="cursor: hand; height: 89px; width: 121px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgeI1uAXo9L0T9Jg10BV1RcSPahC6ZsW1_IQ6P6Hgr4wq77wHc-H4BmpcgDvrleG7AQPC6m-gr1seHGYJBSW37s0G158bQQuN1ZOfQhBQSCDHVilIKjCARa4Xp5VgYzkznrsYwdYwsTEIx-/s1600/raygun19.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607775239354342674" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgeI1uAXo9L0T9Jg10BV1RcSPahC6ZsW1_IQ6P6Hgr4wq77wHc-H4BmpcgDvrleG7AQPC6m-gr1seHGYJBSW37s0G158bQQuN1ZOfQhBQSCDHVilIKjCARa4Xp5VgYzkznrsYwdYwsTEIx-/s200/raygun19.JPG" style="cursor: hand; height: 89px; width: 128px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisoYT1bqXDlLhHtymAtnmsadC3XFl3t4zwYn8X7_6P3cZ7n3RS_FGXlb9-Ri8LzWrKZGiwT3nD-PRntIxlu9h1uAqmHBUqCXdtjH60GwbFfMUcpVY4Np6w1ljrWd7ca14IBUYx4cXTYOZb/s1600/raygun15.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607773248488781458" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisoYT1bqXDlLhHtymAtnmsadC3XFl3t4zwYn8X7_6P3cZ7n3RS_FGXlb9-Ri8LzWrKZGiwT3nD-PRntIxlu9h1uAqmHBUqCXdtjH60GwbFfMUcpVY4Np6w1ljrWd7ca14IBUYx4cXTYOZb/s200/raygun15.JPG" style="cursor: hand; height: 91px; width: 119px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWkUXkN-EVJETzVseM87D_J4IhGwp0DrqMCpDo9TKoc6wSSyaOrWo2T9-Y2NalZg68EjwnPOZn8HbV_64C08OO5Ornp-DbLMwF4RJosXhHox_aQKfl8NTLK_7Zmaz_Uqq78PBb0M_DtmGs/s1600/raygun16.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607773254190939074" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWkUXkN-EVJETzVseM87D_J4IhGwp0DrqMCpDo9TKoc6wSSyaOrWo2T9-Y2NalZg68EjwnPOZn8HbV_64C08OO5Ornp-DbLMwF4RJosXhHox_aQKfl8NTLK_7Zmaz_Uqq78PBb0M_DtmGs/s200/raygun16.JPG" style="cursor: hand; height: 91px; width: 128px;" /></a><br />
This time I decided too add a bit of copper color to the ray gun using paint. I think it looks really cool now. ........Time to vaporize someone with my new ray gun.. :-)<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaMDXqusULGBI6mV1W4CcGZFy_E2LryT35KLbbATVFrSJ7zciOE7yHigEpCGFFbDB0-HcbWI7NkWfBOUDEmsZhg03-vCYzHnEpy_iOwuaZ-LdeviYM5mZdQ501VZcDM0QKNJ5NYy86PTIA/s1600/raygun21.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607775249840934834" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaMDXqusULGBI6mV1W4CcGZFy_E2LryT35KLbbATVFrSJ7zciOE7yHigEpCGFFbDB0-HcbWI7NkWfBOUDEmsZhg03-vCYzHnEpy_iOwuaZ-LdeviYM5mZdQ501VZcDM0QKNJ5NYy86PTIA/s200/raygun21.JPG" style="cursor: hand; height: 114px; width: 169px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpXg7QdQY_bq_Ti8L_pJ3IXmlYTl2Me_iHCJTGYscn44nuxJ0-8URzj5wuqRjmeVsTSALsC6l0zob5-KpxJ8i3BDZbvFfzeE4Ab6Jgh9ueLpXG8lyyQ_RY0uq3V23BJt_3jwq0iar1bxY2/s1600/raygun20.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5607775244806476194" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpXg7QdQY_bq_Ti8L_pJ3IXmlYTl2Me_iHCJTGYscn44nuxJ0-8URzj5wuqRjmeVsTSALsC6l0zob5-KpxJ8i3BDZbvFfzeE4Ab6Jgh9ueLpXG8lyyQ_RY0uq3V23BJt_3jwq0iar1bxY2/s200/raygun20.JPG" style="cursor: hand; height: 113px; width: 158px;" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-1154561073215226742011-05-08T11:42:00.000-07:002013-02-22T05:14:05.626-08:00Sand Casting Aluminum ashtray / bowlThis is a casting I made of a glass ashtray (pattern). In this post I refer to it as a bowl because I am not a smoker. The only small problem was that the inside part of the glass bowl was curved in, so if I would sand mould the glass bowl the way it is the sand mould would break while lifting the cope part, so my solution was to use filler inside the ashtray and smooth the curve the other direction. After the filler was dry I used fine grade sand paper and two coats of clear varnish over it to prevent the sand from sticking. Using glass as a pattern is great because it is very easy to remove it from the sand and the finishing is superb quality. The only thing is while ramming it have to be careful not to break the glass with the rammer.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCEL3nR1OrXO3pY__WU2YiiY_lhpiDYndq4AyNQVLjtzPrzhoDJQJzXVKv7SYeuVl5x7XKarROzT3rMKEAbr89RzKwjE97RouNEPZ8akXx02gNSwbKX1ctd-mb4U2B0MfFj7F-XL14U7G5/s1600/aluminum+ashtray+sand+moulding.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5604420507380641650" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCEL3nR1OrXO3pY__WU2YiiY_lhpiDYndq4AyNQVLjtzPrzhoDJQJzXVKv7SYeuVl5x7XKarROzT3rMKEAbr89RzKwjE97RouNEPZ8akXx02gNSwbKX1ctd-mb4U2B0MfFj7F-XL14U7G5/s200/aluminum+ashtray+sand+moulding.JPG" style="cursor: hand; height: 99px; width: 173px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqQOWGq2rLvsoKp03DsMwqzN79IpkF6zPSV7w11uOU-8-t5mLIQyDGJdKnreE7RuSbcmSItJdiDAbXRrfBwyAdbqzlTKOFSO1FofbL3aCZ20K0dsjehaI2K1Xz1D-t-L7bSBAvPzBESUsi/s1600/ashtray+pattern+and+aluminum+ashtray+casting.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5604420409580991186" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqQOWGq2rLvsoKp03DsMwqzN79IpkF6zPSV7w11uOU-8-t5mLIQyDGJdKnreE7RuSbcmSItJdiDAbXRrfBwyAdbqzlTKOFSO1FofbL3aCZ20K0dsjehaI2K1Xz1D-t-L7bSBAvPzBESUsi/s200/ashtray+pattern+and+aluminum+ashtray+casting.JPG" style="cursor: hand; height: 102px; width: 139px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijELkXHazl4WxF8StxnPdz9zzuSYEkfcv7fcjd8d1zVla_exj_5qUmxDzpk3XpB3lRj419pT_Md4Rkw7p-UExzJrUAWfG3CJbSZaH5uXJEtRKUzWSY1dQMw6_L6kIV-jArGnFrjeKEr7nM/s1600/glass++ashtray+drag+part.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5604425043109535202" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijELkXHazl4WxF8StxnPdz9zzuSYEkfcv7fcjd8d1zVla_exj_5qUmxDzpk3XpB3lRj419pT_Md4Rkw7p-UExzJrUAWfG3CJbSZaH5uXJEtRKUzWSY1dQMw6_L6kIV-jArGnFrjeKEr7nM/s200/glass++ashtray+drag+part.JPG" style="cursor: hand; height: 103px; width: 131px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_ubrnSoBnEUUpLOuMt1HXNoqBUtVeuuwMpIHT93enKvu9XkFfxOCfgG84wNZ922hO0Y0-_MFKGATMQe10eFG5rgNfljJYsy0MeonnMlgmdDS8n7vsNVHXVBEJNhP1XwQ1Stlyn1IUshXh/s1600/glass+ashtray+sand+mould.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5604425045261633010" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_ubrnSoBnEUUpLOuMt1HXNoqBUtVeuuwMpIHT93enKvu9XkFfxOCfgG84wNZ922hO0Y0-_MFKGATMQe10eFG5rgNfljJYsy0MeonnMlgmdDS8n7vsNVHXVBEJNhP1XwQ1Stlyn1IUshXh/s200/glass+ashtray+sand+mould.JPG" style="cursor: hand; height: 100px; width: 141px;" /></a><br />
<span style="color: #000066;">Here is another small tip: As I've mentioned before always preheat your ingot tray and foundry tools that come into contact with the molten aluminum. Another thing that won't do any harm is to preheat the aluminum scarp or ingots before adding them into the crucible. Molten aluminum is 660C° and higher. Two things can happen if parts are not preheated , one is the safety aspect regarding molten metal splashing out of the crucible and the other is thermal shock or "aluminum freeze". The aluminum in the crucible just turns rock hard and back into a molten state after a few minutes.</span><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAya24J_35EU5ZGZi7m5y-Y3HS_J7YlRPxxYyzaKBpvyjFbfGGGyJNggxxTirr8fFlK7x8IyvmNzzVvVJWAEBXWKNEkVYBExbNMUq6qChyphenhyphenMHBHxp1cwyzjbHMsgY4jGp6oqfrtFI4Pcwim/s1600/preheating+aluminum+top.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5604424030875261634" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAya24J_35EU5ZGZi7m5y-Y3HS_J7YlRPxxYyzaKBpvyjFbfGGGyJNggxxTirr8fFlK7x8IyvmNzzVvVJWAEBXWKNEkVYBExbNMUq6qChyphenhyphenMHBHxp1cwyzjbHMsgY4jGp6oqfrtFI4Pcwim/s200/preheating+aluminum+top.JPG" style="cursor: hand; height: 90px; width: 135px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmmfmqrOeeA87ytUhfTkqbusKPkg0D9LFtb9mELXx5lJpq-9aWqRRD-6WFMLeVSJrtpn_0upiZJ16dfQyzbFqKddQ5k5HoexsuMKTSP0mEBB6v5gRka0eY43c8qmIRopVcpyaYoedB15HN/s1600/preheating+aluminum+scarp.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5604424394014613618" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmmfmqrOeeA87ytUhfTkqbusKPkg0D9LFtb9mELXx5lJpq-9aWqRRD-6WFMLeVSJrtpn_0upiZJ16dfQyzbFqKddQ5k5HoexsuMKTSP0mEBB6v5gRka0eY43c8qmIRopVcpyaYoedB15HN/s200/preheating+aluminum+scarp.JPG" style="cursor: hand; height: 89px; width: 131px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIKZ55Z0xbtf30awx9HdikhvdcnDc7br7ltQuE0-YID2BlITNf1xWpuNHTxQEaxXAT9wkA2Yewi9wv8DUNN8ZAM94GTN-liFskwNrTgNKhxabPgxZjsTXzO4STtDeWo-izgcn3W4xfQ_RM/s1600/cope+and+drag+are+open.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5604425919724853554" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIKZ55Z0xbtf30awx9HdikhvdcnDc7br7ltQuE0-YID2BlITNf1xWpuNHTxQEaxXAT9wkA2Yewi9wv8DUNN8ZAM94GTN-liFskwNrTgNKhxabPgxZjsTXzO4STtDeWo-izgcn3W4xfQ_RM/s200/cope+and+drag+are+open.JPG" style="cursor: hand; height: 88px; width: 140px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQ9h_q70X7cRksiIfW8yJ-KzVQXPa5dorqIGtCKQzR8wKcBeCshsp77V3sTGXPhF0KyEHEjnEqj_ZgtcQRslucwMXDAN6S9caIq5OkWWU31t4d1TteM7JAdzJ6mZ3lefOKX8Tl6qpSvrg-/s1600/aluminum+ashtray+with+sprue+and+riser.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5604425911847637042" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQ9h_q70X7cRksiIfW8yJ-KzVQXPa5dorqIGtCKQzR8wKcBeCshsp77V3sTGXPhF0KyEHEjnEqj_ZgtcQRslucwMXDAN6S9caIq5OkWWU31t4d1TteM7JAdzJ6mZ3lefOKX8Tl6qpSvrg-/s200/aluminum+ashtray+with+sprue+and+riser.JPG" style="cursor: hand; height: 88px; width: 134px;" /></a><br />
The aluminum bowl turned out very well now I just have to think of where to put it : -)<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijF-053WowTXpj-4I_fOT9BetvtnnnRaDKf55yh0fCJG7_5Kk-yflwqhLH8kaS07IQLH4M8TV2vkjxfEtA021JMcVfQpSnX9SMLILP8eu8H9_TGLx5GYlG3m7AZAAr4_qNlpVftGKHKXA6/s1600/aluminum+ashtray+and+extra+ingots.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5604425909876909026" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijF-053WowTXpj-4I_fOT9BetvtnnnRaDKf55yh0fCJG7_5Kk-yflwqhLH8kaS07IQLH4M8TV2vkjxfEtA021JMcVfQpSnX9SMLILP8eu8H9_TGLx5GYlG3m7AZAAr4_qNlpVftGKHKXA6/s200/aluminum+ashtray+and+extra+ingots.JPG" style="cursor: hand; height: 82px; width: 146px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkbN9Pw2GowSSUqJuZg2FwHPDKAfayDTzPkvCEoeaTGRj6MwccQDE2wUipjl1a3ur2B9-sDw98CyZo3rsujiSxsEmfJNzkkP6YkiHqm1FlUAF8AkLYJyx_dZpCMbP0GXNGhWuSOT3zKLpK/s1600/aluminum+ashtray+top.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5604425913815088306" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkbN9Pw2GowSSUqJuZg2FwHPDKAfayDTzPkvCEoeaTGRj6MwccQDE2wUipjl1a3ur2B9-sDw98CyZo3rsujiSxsEmfJNzkkP6YkiHqm1FlUAF8AkLYJyx_dZpCMbP0GXNGhWuSOT3zKLpK/s200/aluminum+ashtray+top.JPG" style="cursor: hand; height: 83px; width: 131px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgA-7cnEdqb4HmYJg2PHAEHR-7luKi8IkAVMzEEDYRLpzoks-5Xkw68BzmygsNnQjzobBrAjzFWRFgfw77LqGdMwANMrAHwSpeqHxXy2jiTNzy4DttRu1eSEus_Ygm3VXHyd6-5QUH1Go4j/s1600/aluminum+ashtray+bottom.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5604425907901675170" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgA-7cnEdqb4HmYJg2PHAEHR-7luKi8IkAVMzEEDYRLpzoks-5Xkw68BzmygsNnQjzobBrAjzFWRFgfw77LqGdMwANMrAHwSpeqHxXy2jiTNzy4DttRu1eSEus_Ygm3VXHyd6-5QUH1Go4j/s200/aluminum+ashtray+bottom.JPG" style="cursor: hand; height: 83px; width: 121px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8is5HlW_NDoTXI6Vs_nnZXMLgZyBaehw_gxr7CHp-emnWH_5cQer6P448_YwJ9AVrwVTW_fDCka-r7Z4v-22tQPyz8ISwXBfXhC3Tiz6mFFQT-WGfw3uWPljd6OAiQnRtdYZdQlZ0qrbp/s1600/polished+aluminum+skull++vs+not+polished+ashtray.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5604426790777125666" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8is5HlW_NDoTXI6Vs_nnZXMLgZyBaehw_gxr7CHp-emnWH_5cQer6P448_YwJ9AVrwVTW_fDCka-r7Z4v-22tQPyz8ISwXBfXhC3Tiz6mFFQT-WGfw3uWPljd6OAiQnRtdYZdQlZ0qrbp/s200/polished+aluminum+skull++vs+not+polished+ashtray.JPG" style="cursor: hand; height: 82px; width: 129px;" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-7306679001865243232011-04-29T14:14:00.000-07:002011-05-27T07:11:54.562-07:00Flamingfurnace.com, Aluminum PlaqueThis is a special aluminum casting to celebrate my new flamingfurnace.com Domain.<br />At this stage I'm building my first CNC router machine and it will probably take me sometime to finish it. I found a cheap and easy solution to make my plaque pattern. I used 8mm MDF routing it all around. As for the letters, I got childrens sticky foam letters in a local supermarket (very cheap). After marking the pencil lines for the letters all that was needed was to stick them into place. As past experience tought me MDF is not the best material for a pattern so this time I gave it a few coats of clear varnish and that did the trick.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhk9e2IA8ai9TZEn-Xhi74wrcyCv8xvoPvag37Aup17sd9GpadwBcjO622m77XhntHHep-BHckg0aGWWP3q57CyHe2JM3eYrvy3T8K_-d0OX1XTb2NXHZMOO9klx3F7UNopvu4ErTEqxRxe/s1600/flamingfurnace+aluminum+plaque.JPG"><img style="WIDTH: 149px; HEIGHT: 109px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5601119762889969042" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhk9e2IA8ai9TZEn-Xhi74wrcyCv8xvoPvag37Aup17sd9GpadwBcjO622m77XhntHHep-BHckg0aGWWP3q57CyHe2JM3eYrvy3T8K_-d0OX1XTb2NXHZMOO9klx3F7UNopvu4ErTEqxRxe/s200/flamingfurnace+aluminum+plaque.JPG" /></a> After the pattern was ready I constructed a new flask from some scrap timber. Flasks dimentions: W.600mm H.170mm and the depth is only 80mm (40mm cope 40mm drag) because the pattern is only 12mm in thickness.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiz-i4dabma829BMqxysOeU0PsXI__E12YVEMlIDXLWNfxu5veGTPIuN6ci5VVAGrfpw_bCTlaHTwNSt48iSGVJIBEJLxSc0tMzDrBQ36onA0S4_Fh-LyXMxa0-nZuC29TJczjd3Zn_-Mse/s1600/flamingfurnace+plaque+new++flask.JPG"><img style="WIDTH: 141px; HEIGHT: 91px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5601121190808959874" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiz-i4dabma829BMqxysOeU0PsXI__E12YVEMlIDXLWNfxu5veGTPIuN6ci5VVAGrfpw_bCTlaHTwNSt48iSGVJIBEJLxSc0tMzDrBQ36onA0S4_Fh-LyXMxa0-nZuC29TJczjd3Zn_-Mse/s200/flamingfurnace+plaque+new++flask.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXpRiXzvd5Y_sQ5u0o0CrUj4R-9jsbNKzaODA_iPN5H4yB9tgbdfSH24jJMQlGl6BwtEXyhepvGMXVNdEsg-cYAfxzDk5MuNGQonZ9kJ-Y-lT34wxuHVLd1WSO0NbfPtFwUh0NYewN_422/s1600/CNC+under+construction.JPG"><img style="WIDTH: 145px; HEIGHT: 89px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5601469725793109282" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXpRiXzvd5Y_sQ5u0o0CrUj4R-9jsbNKzaODA_iPN5H4yB9tgbdfSH24jJMQlGl6BwtEXyhepvGMXVNdEsg-cYAfxzDk5MuNGQonZ9kJ-Y-lT34wxuHVLd1WSO0NbfPtFwUh0NYewN_422/s200/CNC+under+construction.JPG" /></a>I started making the sand mould and I was hoping that the gaps I left between the letters and the overall thickness of the letters would be sufficient enough to prevent the sand from sticking between the gaps when lifting the pattern out of the sand.<br /><span style="color:#333399;"><strong>I don't know if I mentioned this before, but if the sand is being rammed too <u>hard</u> it will stick to the pattern when lifting the cope part.</strong><br /><strong>If the sand is rammed to <u>lightly</u> the mould might break and the casting appearance will be damaged. </strong><br /><strong>The trick is to find the right ramming strength balance. </strong><br /><strong>Sometimes a bit of trial and error is needed ;</strong><strong>-) .</strong><br /></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXnLfLIuq0Kd2qhgSMvJ3SJBU0AyOumG4yq1GXofLQn8DBNOYJvLiU2riZ8RVzID3uJ64vghVNcqTlz8JVdjXNfwQvuBfhT2zcM_ngdnUlRvfTG7frKIiyIutLGi77UG9brK6bpQkCw57A/s1600/pattern++liffting+screws.JPG"><img style="WIDTH: 104px; HEIGHT: 78px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5601126067631368642" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXnLfLIuq0Kd2qhgSMvJ3SJBU0AyOumG4yq1GXofLQn8DBNOYJvLiU2riZ8RVzID3uJ64vghVNcqTlz8JVdjXNfwQvuBfhT2zcM_ngdnUlRvfTG7frKIiyIutLGi77UG9brK6bpQkCw57A/s200/pattern++liffting+screws.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgC-EaoJtZVNEQL4UwNiN8_R0JNCzzCc3OMML6UxZ4IE4HPNCH3gvKwb4b8UlKu_y3RzKf3nA7Q75gh9mvh748aETW97FgEF1-F54d13N0IrTCzs0-toP_Z6OeFwzJMnmQhyphenhyphenkAQqQxYW-Kw/s1600/pattern+and++sand+impression.JPG"><img style="WIDTH: 116px; HEIGHT: 78px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5601126062364789666" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgC-EaoJtZVNEQL4UwNiN8_R0JNCzzCc3OMML6UxZ4IE4HPNCH3gvKwb4b8UlKu_y3RzKf3nA7Q75gh9mvh748aETW97FgEF1-F54d13N0IrTCzs0-toP_Z6OeFwzJMnmQhyphenhyphenkAQqQxYW-Kw/s200/pattern+and++sand+impression.JPG" /></a><br />In this casting I didn't use a gating system for the sprue and riser. I only used the sprue and riser feeder extension (pressure head) to prevent aluminum shrinkage. The aluminum feeders really work, I made two identical test castings of aluminum eagles. For the first one I used a sprue riser extension and the other without. The eagle casting without the feeder had shrinkage in a few spots. The eagle casting with the sprue and riser feeder was perfect.<br />In the images you can see three aluminum spikes on the back of the plaque, those are the locations of the venting holes to allow gases out preventing casting defects.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYmmqrM5KUcUzuRxz7BnqZcN06a6PUsDFBtaAslmz2pF06DTtAh0O_ylDRV_9RhA_mMyvrBB5HGrPcThSbXAj4FjIs6o9jS7zbEMBvULq6cLbuJKtZBk-SkcDJ4Jg9TXJlceO3fJGrTSYb/s1600/flask+is+ready+for+aluminum+casting.JPG"><img style="WIDTH: 138px; HEIGHT: 94px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5601129584062002706" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYmmqrM5KUcUzuRxz7BnqZcN06a6PUsDFBtaAslmz2pF06DTtAh0O_ylDRV_9RhA_mMyvrBB5HGrPcThSbXAj4FjIs6o9jS7zbEMBvULq6cLbuJKtZBk-SkcDJ4Jg9TXJlceO3fJGrTSYb/s200/flask+is+ready+for+aluminum+casting.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrDWwPAeGU0vz89aDYkyN9mVeEHvanCjsqwcrM0ToQDopdfuOEWlVnIo_oz0pJevWj6bJSw149DbPZQpeZxI1_i4yccV0P8S7lzUaykAoCRvDtmEW6Y97VnqG8k1ZIGiIMSKhuudGDG9ty/s1600/first+look+after+opening+the+flask.JPG"><img style="WIDTH: 119px; HEIGHT: 93px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5601129568686552498" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrDWwPAeGU0vz89aDYkyN9mVeEHvanCjsqwcrM0ToQDopdfuOEWlVnIo_oz0pJevWj6bJSw149DbPZQpeZxI1_i4yccV0P8S7lzUaykAoCRvDtmEW6Y97VnqG8k1ZIGiIMSKhuudGDG9ty/s200/first+look+after+opening+the+flask.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjV06oyg4U4wzEVMFV5nMAmKnNkO4hBWKUX_0PEh17Y75K1TkroZtjoXjbyIAlXlNRXR7vCWEM9Gv_AZ9Asb9TwBbKncVUuXBXmCOigAs99RCBCEdtZa0vgkbRlCnPClW0UB8_NIBB-aozB/s1600/perfect+aluminum+plaque.JPG"><img style="WIDTH: 125px; HEIGHT: 93px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5601129581040657714" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjV06oyg4U4wzEVMFV5nMAmKnNkO4hBWKUX_0PEh17Y75K1TkroZtjoXjbyIAlXlNRXR7vCWEM9Gv_AZ9Asb9TwBbKncVUuXBXmCOigAs99RCBCEdtZa0vgkbRlCnPClW0UB8_NIBB-aozB/s200/perfect+aluminum+plaque.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjc9-CAw2WCkk7ud9bgfjmnBhEAt8QszjNVNFQdPsjfkDb_xxyXRD19e-hhdiJeUQVaUJ9eNAoeF1mAU5WPKs39HZSziDZjnVNNJUHZeuheKi7YzkIM8WreQ2FFCPaP1LYyvQSTm9k3gdI-/s1600/aluminum+plaque+side.JPG"><img style="WIDTH: 122px; HEIGHT: 92px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5601129575750491090" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjc9-CAw2WCkk7ud9bgfjmnBhEAt8QszjNVNFQdPsjfkDb_xxyXRD19e-hhdiJeUQVaUJ9eNAoeF1mAU5WPKs39HZSziDZjnVNNJUHZeuheKi7YzkIM8WreQ2FFCPaP1LYyvQSTm9k3gdI-/s200/aluminum+plaque+side.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7v4So6eIMRiPVszjrWPxqHGB5SNa4gWg2DZA-qlDc52Tv4FNlnnMnda31fdmYiU_NHashMd-HPGHTO05Fp59babNz27HDomcB8akyoisEACTAJm3h2dtYEhhCGf-LlriCrJ72dvTa6A47/s1600/aluminum+plaque+sprue+and+riser.JPG"><img style="WIDTH: 122px; HEIGHT: 92px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5601129571883911778" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7v4So6eIMRiPVszjrWPxqHGB5SNa4gWg2DZA-qlDc52Tv4FNlnnMnda31fdmYiU_NHashMd-HPGHTO05Fp59babNz27HDomcB8akyoisEACTAJm3h2dtYEhhCGf-LlriCrJ72dvTa6A47/s200/aluminum+plaque+sprue+and+riser.JPG" /></a><br />The plaque turned out very well without any shrinkage or major defects. Plaque size: 495x75x12mm. All the extra aluminum was casted back into ingots. I used again my new buffing wheel with the brown buffing compound. In the image of the cut sprue and riser you can see they did their job by "feeding" the aluminum casting.<br />It's a bit hard to see in the images the shiny finish of the letters but I can see my reflection in them.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUZf9kMIKZgbkFB6F-nHA5np62A1deGXPjJHQynNW_kvITcoi-UkPWQlySmfgkXtNRH-WUWCwW7Fdax43Ad7VqKs755N9n4mg8rbI-D5uGN3DUgWGWXAW33tNrDWOgeMdxYIpuqbp0nMog/s1600/riser+feeding+the+mould.JPG"><img style="WIDTH: 111px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5601133238792584450" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUZf9kMIKZgbkFB6F-nHA5np62A1deGXPjJHQynNW_kvITcoi-UkPWQlySmfgkXtNRH-WUWCwW7Fdax43Ad7VqKs755N9n4mg8rbI-D5uGN3DUgWGWXAW33tNrDWOgeMdxYIpuqbp0nMog/s200/riser+feeding+the+mould.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHeKjokJUDld99Gv73lQVzJhGGTw2iDSuTBTDltBYDtn-r9NaM9LPAZBMPU5z_Kc-AosGcHtJ50g5SboVNe-094fbNc1j_IixktR7txBcrrj0SxdvvABea44IEs5IllCIwKIWISQo1nYEU/s1600/more+aluminum+ingots.JPG"><img style="WIDTH: 93px; HEIGHT: 69px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5601133234472781394" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHeKjokJUDld99Gv73lQVzJhGGTw2iDSuTBTDltBYDtn-r9NaM9LPAZBMPU5z_Kc-AosGcHtJ50g5SboVNe-094fbNc1j_IixktR7txBcrrj0SxdvvABea44IEs5IllCIwKIWISQo1nYEU/s200/more+aluminum+ingots.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioOS-62EGlRGzouPmuV_y63uVk7Ps2zBIh987KmUGvUhVrMam7rzR2bx3vXmVdOQzpKAsPe7H8CsgmCntYpG4Te_1Tuka4d6GV4Gvu5bnseb4YtA3u4R7mmGxY6n9fxSkL5JHYq07VhOpJ/s1600/flamingfurnace+polished+plaqued.JPG"><img style="WIDTH: 120px; HEIGHT: 93px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5601133233273655762" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioOS-62EGlRGzouPmuV_y63uVk7Ps2zBIh987KmUGvUhVrMam7rzR2bx3vXmVdOQzpKAsPe7H8CsgmCntYpG4Te_1Tuka4d6GV4Gvu5bnseb4YtA3u4R7mmGxY6n9fxSkL5JHYq07VhOpJ/s200/flamingfurnace+polished+plaqued.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwC5VSqzz57iGu03UiKcdGNvG0hnUzTKLcUEi6iN2OqfUtRUy0F-upRWEYiITuoJ_Aq_B-a_W_UkhFIzFNJ1IE0aCGeSfiyOAXXchH2UhHsUaIaDUL6Nldn30ZafAGeiGXw_Y7skLLiXmv/s1600/flamingfurnace+plaque.JPG"><img style="WIDTH: 104px; HEIGHT: 92px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5601133231663041026" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwC5VSqzz57iGu03UiKcdGNvG0hnUzTKLcUEi6iN2OqfUtRUy0F-upRWEYiITuoJ_Aq_B-a_W_UkhFIzFNJ1IE0aCGeSfiyOAXXchH2UhHsUaIaDUL6Nldn30ZafAGeiGXw_Y7skLLiXmv/s200/flamingfurnace+plaque.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrm30fHOz990uhf4pupl2UpEhmmW8fhZmfGXfFHv0yj58rLio8BCFnJemLw-FaECA5p4bLoTCb-mdMvxhCKtg-o91EaMhOlIiixVlpSHUUUO0FAZnYb-IFep3BUzzcHwVJuUMduJkVsr09/s1600/flamingfurnace.com+aluminum+plaque+casting.bmp"><img style="WIDTH: 200px; HEIGHT: 92px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5601509824034684802" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrm30fHOz990uhf4pupl2UpEhmmW8fhZmfGXfFHv0yj58rLio8BCFnJemLw-FaECA5p4bLoTCb-mdMvxhCKtg-o91EaMhOlIiixVlpSHUUUO0FAZnYb-IFep3BUzzcHwVJuUMduJkVsr09/s200/flamingfurnace.com+aluminum+plaque+casting.bmp" /></a><br />I took this image after painting the aluminum plaque with copper paint.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjHb2GnK_XuCd7bSBJxsWcdbrhl8zuFLsSAl6ma2PFSikXQ6M6gdlF7dxD6JFEmHZ2A2C5-Id8EQwO8yDrizyfc92NJCWYtsD67bZd7RYZm-u5WRNovg0Xt6k3f3mgbOp2bcjgnxESDfkG/s1600/flaming+flamingfurnace.jpg"><img style="WIDTH: 159px; HEIGHT: 103px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5611398122082251442" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjHb2GnK_XuCd7bSBJxsWcdbrhl8zuFLsSAl6ma2PFSikXQ6M6gdlF7dxD6JFEmHZ2A2C5-Id8EQwO8yDrizyfc92NJCWYtsD67bZd7RYZm-u5WRNovg0Xt6k3f3mgbOp2bcjgnxESDfkG/s200/flaming+flamingfurnace.jpg" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-56735468165044382042011-04-16T06:01:00.000-07:002013-01-04T12:00:24.149-08:00Small Aluminum Skull Sand Casting In this post I will explain how I sand casted an aluminum skull. This is one of my favourite aluminum objects that I've I casted, it turned out very well. I had this small cast skull on the shelf for the last 30 years I don't even know its origin. I decided to make an aluminum duplicate using it as a pattern. It took me three time to make the cope part but again it was worth it in the end. I also got myself a new buffing wheel and a brown polishing buffing compound (500g soap wax bar) for this project.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1YTb8Zat2IcfoGn5CvbazaGPF9Fo4jl0ZNgDcD_vecjOzUGw9qCZpA4mdtnOaenn0wF2n-o6dIp-y1x0rxZjQFJjZMvcXEEccny02gjM3ZF9Q8e-tXMUbxCbBvPy0RZgsUAn_V8PIw1l4/s1600/sand+casting+aluminum+skull.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5596169090131737826" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1YTb8Zat2IcfoGn5CvbazaGPF9Fo4jl0ZNgDcD_vecjOzUGw9qCZpA4mdtnOaenn0wF2n-o6dIp-y1x0rxZjQFJjZMvcXEEccny02gjM3ZF9Q8e-tXMUbxCbBvPy0RZgsUAn_V8PIw1l4/s200/sand+casting+aluminum+skull.JPG" style="cursor: hand; height: 91px; width: 153px;" /></a> I also experimented by using only one sprue without a riser and it turned out very well.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0v6YF6CwcxkqZsNPzh-dKoCYCY-JlPAtYReWyDxk9Co_xf3HMcKkLqvEjUahlqLLh4Jch3Hxe3zZRuE8uohQpvGhAwaKb4HQVXxHWSg4bjbxX66uWyhc93XJ7AceCyGFMPUYsxUnOJptm/s1600/aluminum+skull+and+sprue.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5596267735649672866" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0v6YF6CwcxkqZsNPzh-dKoCYCY-JlPAtYReWyDxk9Co_xf3HMcKkLqvEjUahlqLLh4Jch3Hxe3zZRuE8uohQpvGhAwaKb4HQVXxHWSg4bjbxX66uWyhc93XJ7AceCyGFMPUYsxUnOJptm/s200/aluminum+skull+and+sprue.JPG" style="cursor: hand; height: 84px; width: 120px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKBYRnIpwFUKpKXX8dyjI7fFv3n-WvFjQcqsLhRPRJ81C0MOqk3fxQRZ2epPOvBaDsvK9kYrzLDJ-oWpS6CYfI85QTwYDbWxkFkz4ucLyHBSBmwQWhCsU1kxhER44AxfmblLV70FX1-YLU/s1600/aluminum+skull+base.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5596267742190500962" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKBYRnIpwFUKpKXX8dyjI7fFv3n-WvFjQcqsLhRPRJ81C0MOqk3fxQRZ2epPOvBaDsvK9kYrzLDJ-oWpS6CYfI85QTwYDbWxkFkz4ucLyHBSBmwQWhCsU1kxhER44AxfmblLV70FX1-YLU/s200/aluminum+skull+base.JPG" style="cursor: hand; height: 83px; width: 124px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYNSEcs9ZIncKDatBMoqsDvyr2lhwRvuRVPH_Pv0IipgbZsgNKZw4J0zdsDzlUUxtSOYRcWRj9o7MkWrjZjYNeofrtsiPqYYXSJqHNZRAEoiipIiCTxw3ZvUU2LwErFKulpJcvhJ089Wy0/s1600/aluminum+skull+and+pattern.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5596267735398641490" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYNSEcs9ZIncKDatBMoqsDvyr2lhwRvuRVPH_Pv0IipgbZsgNKZw4J0zdsDzlUUxtSOYRcWRj9o7MkWrjZjYNeofrtsiPqYYXSJqHNZRAEoiipIiCTxw3ZvUU2LwErFKulpJcvhJ089Wy0/s200/aluminum+skull+and+pattern.JPG" style="cursor: hand; height: 82px; width: 128px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMFB89i1R3XIKRKkaOdpML3-CJSGUlZlhzrLwNFb7JKfy76x0O497rXbeQKq-uehdpCwuj3bkjWtAf_qNmSHCroTegyYSNF9oQYqdH3N8Z1cl9bHzfG3qGM0VCI6bj4_Fpi2DCiOSk8o6L/s1600/front+aluminum+skull+before+polish.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5596267745545260850" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMFB89i1R3XIKRKkaOdpML3-CJSGUlZlhzrLwNFb7JKfy76x0O497rXbeQKq-uehdpCwuj3bkjWtAf_qNmSHCroTegyYSNF9oQYqdH3N8Z1cl9bHzfG3qGM0VCI6bj4_Fpi2DCiOSk8o6L/s200/front+aluminum+skull+before+polish.JPG" style="cursor: hand; height: 83px; width: 130px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlnLeIRHh5SLw8Ztdh1cIph-SSI8Gzz11oNE9L5eXegqyqKbJm9W0r_Qytsk-bere4-irzADwbfqt9P9ccqJ0KN2ojtw0uz1K3Cze-9fuNy01EGx88QFGalG2wmRcCR-wFaSM_YZ73huaI/s1600/back+aluminum+skull+before+polish.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5596267741399295266" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlnLeIRHh5SLw8Ztdh1cIph-SSI8Gzz11oNE9L5eXegqyqKbJm9W0r_Qytsk-bere4-irzADwbfqt9P9ccqJ0KN2ojtw0uz1K3Cze-9fuNy01EGx88QFGalG2wmRcCR-wFaSM_YZ73huaI/s200/back+aluminum+skull+before+polish.JPG" style="cursor: hand; height: 86px; width: 132px;" /></a> After cutting the sprue I started with the polish proccess. First I used some sand paper and metal wool coarse and fine grades and after that I used my new buffing wheel with the brown polish compound. It didn't take long until I saw a nice shine glowing from the skull. After more polishing I could see my reflection on the skull and I am happy with that at the moment. <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJC9-X0wfI9A6EIF1isjbAhyT1JMXmSyn_zjH4xCaF3ZsNtmUX8FWJAeYX4lNBQ0XV_uoeVJ5E7KWtIpZyTidt7rM7G56dPOxdgUxxABQbdDW2Dr0CwMyKEC5W_klin_80G9vqtmO-5yoU/s1600/brown+polish+block1.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5596271371645178962" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJC9-X0wfI9A6EIF1isjbAhyT1JMXmSyn_zjH4xCaF3ZsNtmUX8FWJAeYX4lNBQ0XV_uoeVJ5E7KWtIpZyTidt7rM7G56dPOxdgUxxABQbdDW2Dr0CwMyKEC5W_klin_80G9vqtmO-5yoU/s200/brown+polish+block1.JPG" style="cursor: hand; height: 83px; width: 137px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdmLm6WU2JL8NSoMM44cs3qpFllapnuYv4y02UNiTGyfsNDn5Utbb6I4chfOJ7vxM5L5Q0wKejYdHaH0XimE2gq2y8SQp-Z6_zc59wCajuUDe8WxeNb-eRKMR-rzxlZjDbMiNUlI3uDt34/s1600/brown+polish+block2.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5596271377013025058" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdmLm6WU2JL8NSoMM44cs3qpFllapnuYv4y02UNiTGyfsNDn5Utbb6I4chfOJ7vxM5L5Q0wKejYdHaH0XimE2gq2y8SQp-Z6_zc59wCajuUDe8WxeNb-eRKMR-rzxlZjDbMiNUlI3uDt34/s200/brown+polish+block2.JPG" style="cursor: hand; height: 81px; width: 128px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgp_IC-BGJqBgcWgQ21jZrII8K_33mRdKzoOGglBK6x952CMOC4A_Jovbdi0E3tiSdxmcRrW6spNEKP-hnU80S74eJYMLgEV5FE9op5BbP2GWCxH14TKopodebAZqTa4Wwf-o_JOEAp9jX9/s1600/polished+aluminum+skull.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5596271362187824130" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgp_IC-BGJqBgcWgQ21jZrII8K_33mRdKzoOGglBK6x952CMOC4A_Jovbdi0E3tiSdxmcRrW6spNEKP-hnU80S74eJYMLgEV5FE9op5BbP2GWCxH14TKopodebAZqTa4Wwf-o_JOEAp9jX9/s200/polished+aluminum+skull.JPG" style="cursor: hand; height: 103px; width: 149px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHGewnHL2v0uPfDdizszZcqPhM3mnX7eZ4rWCjTbZnT5Z-v-5wcC-yjoR6xpuLGW25lR1VzDSn5oioaQZf0pum7-gPBfy7225BSRj1NI2LTKk_gP1ZAM4IgysjZA2DogohbRhflkh8OdJK/s1600/aluminum+skull+before+and+after+polish.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5596271359955137490" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHGewnHL2v0uPfDdizszZcqPhM3mnX7eZ4rWCjTbZnT5Z-v-5wcC-yjoR6xpuLGW25lR1VzDSn5oioaQZf0pum7-gPBfy7225BSRj1NI2LTKk_gP1ZAM4IgysjZA2DogohbRhflkh8OdJK/s200/aluminum+skull+before+and+after+polish.JPG" style="cursor: hand; height: 102px; width: 151px;" /></a> Here are a few more images of the aluminum skull nice and shiny. I use it now as my paper weight and pen holder.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRBN4gD1S0EwACbTF36d_pWzy9-LFVC2dfcRB42miKrGZBOywTYFjsvu911IEuv6PDA0sjWLmDkW4BKXi98pBYs0hB0y0t_iED28UI_2AR1MNWfYs8pF545Q_MSjtJ9lmHpsJjcjuPyNvw/s1600/polished+aluminum+skull4.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5596274658936512226" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRBN4gD1S0EwACbTF36d_pWzy9-LFVC2dfcRB42miKrGZBOywTYFjsvu911IEuv6PDA0sjWLmDkW4BKXi98pBYs0hB0y0t_iED28UI_2AR1MNWfYs8pF545Q_MSjtJ9lmHpsJjcjuPyNvw/s200/polished+aluminum+skull4.JPG" style="cursor: hand; height: 84px; width: 126px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiW2CmTrsS8VGqYjFvS2Un9XilU2OZb7f23-qVWye8E6QGUxjLck_TAFghA2TjE4nmqlTUMHdpshNHdbyYs_mnpZF8Zg5ysz-st6crIj-jrZmROu-yr23ancYfR1dspxfNXdkDspezXZgeJ/s1600/polished+aluminum+skull3.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5596274658276463570" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiW2CmTrsS8VGqYjFvS2Un9XilU2OZb7f23-qVWye8E6QGUxjLck_TAFghA2TjE4nmqlTUMHdpshNHdbyYs_mnpZF8Zg5ysz-st6crIj-jrZmROu-yr23ancYfR1dspxfNXdkDspezXZgeJ/s200/polished+aluminum+skull3.JPG" style="cursor: hand; height: 85px; width: 117px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh08vIlEPGi8DP-WJuiEmT0qkTlhia8xD_mC23pdq413YIDHmAII_CJqvUEYAZCmkDbGs5saEbu-0e3i-v6_gFmbQAzsQoG1HpArU5Y_9wq17nFigfkpWlejjSCzmblIjummAXugyjRIlxw/s1600/polished+aluminum+skull2.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5596274653952503154" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh08vIlEPGi8DP-WJuiEmT0qkTlhia8xD_mC23pdq413YIDHmAII_CJqvUEYAZCmkDbGs5saEbu-0e3i-v6_gFmbQAzsQoG1HpArU5Y_9wq17nFigfkpWlejjSCzmblIjummAXugyjRIlxw/s200/polished+aluminum+skull2.JPG" style="cursor: hand; height: 84px; width: 131px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWcJkxgyPsehse1bgu5IqH3lVgF0U4yWkdEue_uMvKRuttJaIniIxRGo0UDpmCwCoRKglH9m-h1dqPbGInUx-ferAf-RB_VkGYglhSbipBIJPEc8_pVVLloTVa57-OsUmymQey9SbpAE6k/s1600/polished+aluminum+skull1.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5596274651714146034" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWcJkxgyPsehse1bgu5IqH3lVgF0U4yWkdEue_uMvKRuttJaIniIxRGo0UDpmCwCoRKglH9m-h1dqPbGInUx-ferAf-RB_VkGYglhSbipBIJPEc8_pVVLloTVa57-OsUmymQey9SbpAE6k/s200/polished+aluminum+skull1.JPG" style="cursor: hand; height: 83px; width: 127px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjisb8MI_RFxzQft4wZ7pBWu2fi4bPxHxrM1ef5S7JGAqslAKhsu4CPRvsqwhXEmQiBstQo2lO1QOQ8huca6EIbltV_X6-AH5S3VmTv-8Qzl__fEC1UJoXIgmJX5M_1ogudNNk4wvQxGpmS/s1600/aluminum+paper+wight+skull.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5596274647887499666" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjisb8MI_RFxzQft4wZ7pBWu2fi4bPxHxrM1ef5S7JGAqslAKhsu4CPRvsqwhXEmQiBstQo2lO1QOQ8huca6EIbltV_X6-AH5S3VmTv-8Qzl__fEC1UJoXIgmJX5M_1ogudNNk4wvQxGpmS/s200/aluminum+paper+wight+skull.JPG" style="cursor: hand; height: 82px; width: 125px;" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-61560588484475418042011-03-12T13:51:00.000-08:002013-02-22T08:47:01.173-08:00Aluminum lizard sand castingIn this sand casting project I used one sprue and two risers making sure the mould cavity would be full with molten aluminum and enough aluminum to "feed"the casting without having any shrinkage.
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<img alt="" border="0" id="BLOGGER_PHOTO_ID_5583316186095937282" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBHsQD4wIYwj3DtJd37aj-41z6-xNFWdJDihHgaCZFL5MdnfO8gGijewT4-_mdrOu4PBRqknA4gcWSeLJrLBHS2InqamHZIdrIpLI2pbPXrTdR64wRxsF34JeaZsJ6lIpc7kL2Qwk7vuFO/s200/DSCF0103+%2528Small%2529.JPG" style="cursor: hand; height: 95px; width: 153px;" /> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZAQAMkDKvXxlGEpJ-4XC1sWlXZ6Sf5SEyY3NW4RUMBq4vCehBZNgrIYKabsUrj4TiZnM0AP91qojEExeDLy_R_-jgYGCm3amM4gHPfpDj3L3XSWdCoQ4IYmAWaP3gXPeXsL6ycdmobsTQ/s1600/DSCF0113+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5583316189766764866" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZAQAMkDKvXxlGEpJ-4XC1sWlXZ6Sf5SEyY3NW4RUMBq4vCehBZNgrIYKabsUrj4TiZnM0AP91qojEExeDLy_R_-jgYGCm3amM4gHPfpDj3L3XSWdCoQ4IYmAWaP3gXPeXsL6ycdmobsTQ/s200/DSCF0113+%2528Small%2529.JPG" style="cursor: hand; height: 105px; width: 161px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizQXL9ByU3hmMOvbZ3j3bsdvkNw1VQ_gTQH3oeG-6d3pTiLLVF5hHEHyZkjrpvryugylt7_cJa5BdNhVUJ47GWOoQ57eUQby48GEr32vp2eJQrWRjc73WKiUSvBw7Opgl2960-SIZgp-TG/s1600/DSCF0112+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5583316192366456290" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizQXL9ByU3hmMOvbZ3j3bsdvkNw1VQ_gTQH3oeG-6d3pTiLLVF5hHEHyZkjrpvryugylt7_cJa5BdNhVUJ47GWOoQ57eUQby48GEr32vp2eJQrWRjc73WKiUSvBw7Opgl2960-SIZgp-TG/s200/DSCF0112+%2528Small%2529.JPG" style="cursor: hand; height: 97px; width: 135px;" /></a>
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Making a mould with a pattern that is flat on one side is very easy and it didn't take too long to prepare.
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi15zR-s5qIMdJSWQFaB8pE1qeBfjlymWKJWz9ZYiM8-Mi-Mi2xdFChhm0HT1cAhGMxjfp-7CvMHZ1_CRk3oj52Z0o99HXoJk6thYkG5L-iHDiKNgSNhsoMsbE9c5QhEB54siBJiwW2QvQH/s1600/DSCF0126+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5583317763822140786" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi15zR-s5qIMdJSWQFaB8pE1qeBfjlymWKJWz9ZYiM8-Mi-Mi2xdFChhm0HT1cAhGMxjfp-7CvMHZ1_CRk3oj52Z0o99HXoJk6thYkG5L-iHDiKNgSNhsoMsbE9c5QhEB54siBJiwW2QvQH/s200/DSCF0126+%2528Small%2529.JPG" style="cursor: hand; height: 82px; width: 137px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCm-2NdegS1K9AkH6b3VohO_QaxwX8Hu1gFX9oPnJ8hbC3fsbNEnNEp1cE5O2E9b-krJoE15EmgZPigcZyDan_KXK_QfDj19oj8h-GVN-8mSC_XzyNBTiGlYVZIqCeqKyTUBPI6nd-4Hm-/s1600/DSCF0149+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5583317765150559218" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCm-2NdegS1K9AkH6b3VohO_QaxwX8Hu1gFX9oPnJ8hbC3fsbNEnNEp1cE5O2E9b-krJoE15EmgZPigcZyDan_KXK_QfDj19oj8h-GVN-8mSC_XzyNBTiGlYVZIqCeqKyTUBPI6nd-4Hm-/s200/DSCF0149+%2528Small%2529.JPG" style="cursor: hand; height: 82px; width: 129px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivXatgw6vb9TEjjR9cMrBHk6n6h_r24xv9m7reGgZ1_TmuFveY_dRUjtZrGpjS9dl22RMabylsOLvU0RW2tyiMQfOjHBUz6XEaDQkfMGJSWEKa_Hp1uwy9aT0fbtXd4uc_uInkfjP1UI9W/s1600/DSCF0124+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5583317758624467474" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivXatgw6vb9TEjjR9cMrBHk6n6h_r24xv9m7reGgZ1_TmuFveY_dRUjtZrGpjS9dl22RMabylsOLvU0RW2tyiMQfOjHBUz6XEaDQkfMGJSWEKa_Hp1uwy9aT0fbtXd4uc_uInkfjP1UI9W/s200/DSCF0124+%2528Small%2529.JPG" style="cursor: hand; height: 83px; width: 117px;" /></a>
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In the image you can see that the risers did their part by feeding the mould and preventing casting defects.
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihts4C_oPan09mS1sIxJSAy9LObJsYIRiCCmTsB2HaOJ1kb01ONgEAPADBFEBY8y8Ee-P2CP011dh9e937Jp5UWUOFwqhEA2ytnWeMZm5FgmtWxM2Q6eMgqWK5MoeZEzgkdZcyHdcnKVir/s1600/DSCF0213+%2528Small%2529.JPG"><img alt="sand casting sprue riser" border="0" id="BLOGGER_PHOTO_ID_5583317773805890786" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihts4C_oPan09mS1sIxJSAy9LObJsYIRiCCmTsB2HaOJ1kb01ONgEAPADBFEBY8y8Ee-P2CP011dh9e937Jp5UWUOFwqhEA2ytnWeMZm5FgmtWxM2Q6eMgqWK5MoeZEzgkdZcyHdcnKVir/s200/DSCF0213+%2528Small%2529.JPG" style="height: 95px; width: 143px;" title="Foundy sand casting sprue riser" /></a> The finished Aluminum lizard------><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhw0cEVrDGAfoMLF1To11mX5LsZ2dbTlt-tBLzlamKyLLiiRP4Tg3ce3Be2vYTnwAhdMqx36HhPKs11Y78rcwebCfPzhpBG7MnfvwydKhH2KNJjWIj2xa7heWF2sgl6I89pJ_jSBqLyOqiS/s1600/DSCF0248+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5583320006576604050" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhw0cEVrDGAfoMLF1To11mX5LsZ2dbTlt-tBLzlamKyLLiiRP4Tg3ce3Be2vYTnwAhdMqx36HhPKs11Y78rcwebCfPzhpBG7MnfvwydKhH2KNJjWIj2xa7heWF2sgl6I89pJ_jSBqLyOqiS/s200/DSCF0248+%2528Small%2529.JPG" style="cursor: hand; height: 107px; width: 147px;" /></a>
<br />
<u>This is my II aluminum lizard casting I made on July 2011:</u>
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglZX9cNecPGT6dohqykLvfrjZLAjb7LzVl6l5Q2g4vK34c_tnaB8RA1JZyecXwZ1wX9lLCnuXpese-h7cznKoC0dwKSOrpW2lBLhmoWAZMVlnFr7o9SqfLS_dNc-M7r0L99EIlOexmm5-z/s1600/DSCF0108+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641572955467330034" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglZX9cNecPGT6dohqykLvfrjZLAjb7LzVl6l5Q2g4vK34c_tnaB8RA1JZyecXwZ1wX9lLCnuXpese-h7cznKoC0dwKSOrpW2lBLhmoWAZMVlnFr7o9SqfLS_dNc-M7r0L99EIlOexmm5-z/s200/DSCF0108+%2528Small%2529.JPG" style="cursor: hand; height: 100px; width: 144px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhw95P9HUsgCiKGX06dCKk3vc4DAo5-huh7GLkN6CSYO0haWJvJXeYt_QhbpOKHUhV8MyicU7-50QvWLtOGhglmGcXRs3-Mt_dqCyHoByK_33pinhaXKL99A6OEuVKTw4xnShCLfOtAiWvD/s1600/DSCF0103+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641572937509472034" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhw95P9HUsgCiKGX06dCKk3vc4DAo5-huh7GLkN6CSYO0haWJvJXeYt_QhbpOKHUhV8MyicU7-50QvWLtOGhglmGcXRs3-Mt_dqCyHoByK_33pinhaXKL99A6OEuVKTw4xnShCLfOtAiWvD/s200/DSCF0103+%2528Small%2529.JPG" style="cursor: hand; height: 98px; width: 143px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3G_ajzmDwE9d7kYsAwFeuxbJQWVastwdo_eUznJLSTFgix5x_wSsRngyRTcZHem4LiBbuL47bZZw2ETYvD8ANijiZ75AvoDN6Jhg95OfRoe1ekZLD8bnKoSAKWH0NxD2dX_WMFn-CCMl0/s1600/DSCF0098+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641572933834809906" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3G_ajzmDwE9d7kYsAwFeuxbJQWVastwdo_eUznJLSTFgix5x_wSsRngyRTcZHem4LiBbuL47bZZw2ETYvD8ANijiZ75AvoDN6Jhg95OfRoe1ekZLD8bnKoSAKWH0NxD2dX_WMFn-CCMl0/s200/DSCF0098+%2528Small%2529.JPG" style="cursor: hand; height: 96px; width: 149px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgq4jjxkzeYC5B4R0UhNvqBPK7eUU5ph_DTpFZ5nQpEPXDXYgltOLpeRUhVCm68J5gIcGfEE90x-WSynANtUYJ7JN6P5KToGVwIjI0q0dEn5lXYH6GKy19oVNjruPCwFtObBxhdfTZrtR1m/s1600/DSCF0092+%2528Small%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5641572922486063090" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgq4jjxkzeYC5B4R0UhNvqBPK7eUU5ph_DTpFZ5nQpEPXDXYgltOLpeRUhVCm68J5gIcGfEE90x-WSynANtUYJ7JN6P5KToGVwIjI0q0dEn5lXYH6GKy19oVNjruPCwFtObBxhdfTZrtR1m/s200/DSCF0092+%2528Small%2529.JPG" style="cursor: hand; height: 96px; width: 139px;" /></a>
FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-54603446918718670762011-03-03T15:13:00.000-08:002011-04-15T13:51:03.066-07:00Aluminum eagle sand castingThis week I sand casted an aluminum eagle. The eagle pattern is relatively flat so it's an easy and quick job to make the sand mould. I got more scrap aluminum from a baby pram frame and some un-used aluminum crutches. After stripping all the plastic parts and braking the aluminum so it will fit into my crucible I got plenty of molten aluminum alloy to keep me going for a few more projects. <br><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinpWwmuYkU90JKJpWxTrxyF7uvSYeJGS8DaT1eqNc6e16ghiAZR-6mY1zXMf8DFL8kx9cf2HqpnKCFArFVyke-txoRZlvyX5feO096z5ovUb19dmqitsh1fMctNTkyhnGVzc7Oxi1CN7yx/s1600/aluminum+pile.JPG"><img style="WIDTH: 88px; HEIGHT: 58px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5579999653417221970" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinpWwmuYkU90JKJpWxTrxyF7uvSYeJGS8DaT1eqNc6e16ghiAZR-6mY1zXMf8DFL8kx9cf2HqpnKCFArFVyke-txoRZlvyX5feO096z5ovUb19dmqitsh1fMctNTkyhnGVzc7Oxi1CN7yx/s200/aluminum+pile.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijcMj9D0h_AMY0eurU1HucPbq0c9ocsnJ-byD-WZMBdWZtKI1iibXGXO_M2peFjUQIdEuI7QVaD5Y0-mNIUGt7evreUNncIYEszPoTzBLNdfOnh7TS7z9ZlbrGRS0rNSXI_mKW1V8GQsCB/s1600/aluminum+scrap.JPG"><img style="WIDTH: 82px; HEIGHT: 57px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5579999729950233842" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijcMj9D0h_AMY0eurU1HucPbq0c9ocsnJ-byD-WZMBdWZtKI1iibXGXO_M2peFjUQIdEuI7QVaD5Y0-mNIUGt7evreUNncIYEszPoTzBLNdfOnh7TS7z9ZlbrGRS0rNSXI_mKW1V8GQsCB/s200/aluminum+scrap.JPG" /></a> <br>After making the mould I started to melt the aluminum alloy. The melting process was very quick, most of the aluminum parts were thin and they are no match for the high tempature of the foundry. Only two scoops of <br><a href="http://flamingfurnace.blogspot.com/p/foundry-terminology.html">dross</a> needed to be skimmed off, so I got plenty of molten aluminum.<br> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRcMUcWsqWfG82F4koPYyx6nWptrBddPN6ET6oe78CRuSrrk1NPgGZCajvE1q7bpLmHu4NQm978oveD1pbOv4w_-Av6nkTiFZRCfVoGfHcOdJhOH6S3LubYBGuRzmG8xMrgBKy5hww5hfj/s1600/sand+rammer.JPG"><img style="WIDTH: 109px; HEIGHT: 70px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5580001153619723218" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRcMUcWsqWfG82F4koPYyx6nWptrBddPN6ET6oe78CRuSrrk1NPgGZCajvE1q7bpLmHu4NQm978oveD1pbOv4w_-Av6nkTiFZRCfVoGfHcOdJhOH6S3LubYBGuRzmG8xMrgBKy5hww5hfj/s200/sand+rammer.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVLZwcpWMjadXyl5FAgl7s7ggpgEKX2mTX2RpBKOgwxG84VPD7Smwgz8ZIVGcbvdL25Ri1WZ2oTCRsaOyTitDAX5a2NnRGsng7KBO2bQtz7BkYrqXxhyphenhyphenh002hLjcKAAPdOF5OxdnDfWakn/s1600/eagle+pattern+impresion+A.JPG"><img style="WIDTH: 100px; HEIGHT: 71px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5580001161526234722" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVLZwcpWMjadXyl5FAgl7s7ggpgEKX2mTX2RpBKOgwxG84VPD7Smwgz8ZIVGcbvdL25Ri1WZ2oTCRsaOyTitDAX5a2NnRGsng7KBO2bQtz7BkYrqXxhyphenhyphenh002hLjcKAAPdOF5OxdnDfWakn/s200/eagle+pattern+impresion+A.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisUsVwD5zXie5SeJmskKRzkmEkFWhxKSqHzXOCNSy6Gugadpe3lv2so60byf_ZeAuhjfuj0C3M9ac0eJfltqx3j0q_pvrtTFnvooMlhF9Dasz3F7Hh6lsT2iXDItZ9iXJ3y3PTtvthJCAB/s1600/pattern+impresion+B.JPG"><img style="WIDTH: 122px; HEIGHT: 70px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5580001158549088098" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisUsVwD5zXie5SeJmskKRzkmEkFWhxKSqHzXOCNSy6Gugadpe3lv2so60byf_ZeAuhjfuj0C3M9ac0eJfltqx3j0q_pvrtTFnvooMlhF9Dasz3F7Hh6lsT2iXDItZ9iXJ3y3PTtvthJCAB/s200/pattern+impresion+B.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihbSMeH-8yuo8fXaB01rCS4syZs_wgzOcDD6CpdbHVhyS5r04to_q4F-RYw0vgQyFqp7cOMcJAbPzyPkansSne8y2D2VcrVOzB1JROSc2iG6FJHs19Z28SwIUJY8h86gteIDF8h7VIz9js/s1600/aluminum+cooling+in+flask.JPG"><img style="WIDTH: 115px; HEIGHT: 72px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5580001169123635554" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihbSMeH-8yuo8fXaB01rCS4syZs_wgzOcDD6CpdbHVhyS5r04to_q4F-RYw0vgQyFqp7cOMcJAbPzyPkansSne8y2D2VcrVOzB1JROSc2iG6FJHs19Z28SwIUJY8h86gteIDF8h7VIz9js/s200/aluminum+cooling+in+flask.JPG" /></a><br> Here are a few images of the aluminum eagle after the aluminum cooled down and I opened the flask.<br> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPuQfDHRK8M6dZnIw4_XfTdWp86RyHUXns6D05qj74MywVhZU9-eMgiWKKslKZKZS_7_XiwFPT2HAvVmb_EZ9CWG66TPcAYjtQdYxdPbHi-kVI4td5fpzMlxZeyKbT4GFHCGsZj7fPg-Hn/s1600/aluminum+eagleA.JPG"><img style="WIDTH: 127px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5580003339035739554" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPuQfDHRK8M6dZnIw4_XfTdWp86RyHUXns6D05qj74MywVhZU9-eMgiWKKslKZKZS_7_XiwFPT2HAvVmb_EZ9CWG66TPcAYjtQdYxdPbHi-kVI4td5fpzMlxZeyKbT4GFHCGsZj7fPg-Hn/s200/aluminum+eagleA.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3d7MHrP50n0-A1Dlak9qDeg8ZBSTf418vvNg_BpqP1icdKezuBMhF-EnxsjmLkZM1CmXqSHyF6Sg_xQ5fNA5O3VdhN0kRhM03hgKt6vzvFQ7w7POFmPdiYnCNFSA5lwQzY7EMMtLjB0RX/s1600/aluminum+eagleB.jpg"><img style="WIDTH: 127px; HEIGHT: 84px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5580003337986200178" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3d7MHrP50n0-A1Dlak9qDeg8ZBSTf418vvNg_BpqP1icdKezuBMhF-EnxsjmLkZM1CmXqSHyF6Sg_xQ5fNA5O3VdhN0kRhM03hgKt6vzvFQ7w7POFmPdiYnCNFSA5lwQzY7EMMtLjB0RX/s200/aluminum+eagleB.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwCTPoaV53FhLwBQQMniE6on-_G5pGGsiSavXnmby1L8oquYV1MwfLzlMh4rVW5adp6YvVifEvmAyNQnaHGDyUMCBNu9hkNot38kgtYxZFBRpB5G9rbkuRWY_PnffNwclMdmrqncVLoo-B/s1600/DSCN5074+%2528Small%2529.JPG"><img style="WIDTH: 131px; HEIGHT: 87px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5580692547599896018" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwCTPoaV53FhLwBQQMniE6on-_G5pGGsiSavXnmby1L8oquYV1MwfLzlMh4rVW5adp6YvVifEvmAyNQnaHGDyUMCBNu9hkNot38kgtYxZFBRpB5G9rbkuRWY_PnffNwclMdmrqncVLoo-B/s200/DSCN5074+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiebq3zg-i5UTyJXggdpRUzhRj7fx4sFWMQstMvtvHCai_wAdYbN_2A8deUQUX8ENNIgSgrYsAeXscamHWli7qGTRn0DuPymzECoO2bdxlluij2exvoNjN5CqqcwaRctvPVXSSCAJ4WtBj3/s1600/DSCN5081+%2528Small%2529.JPG"><img style="WIDTH: 124px; HEIGHT: 86px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5580692546337175666" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiebq3zg-i5UTyJXggdpRUzhRj7fx4sFWMQstMvtvHCai_wAdYbN_2A8deUQUX8ENNIgSgrYsAeXscamHWli7qGTRn0DuPymzECoO2bdxlluij2exvoNjN5CqqcwaRctvPVXSSCAJ4WtBj3/s200/DSCN5081+%2528Small%2529.JPG" /></a><br> Nothing goes to waste all the extra aluminum is turned into ingots.<br> <a href="http://flamingfurnace.blogspot.com/2011/02/sand-casting-terminology.html">Sprue and Riser </a>are cut off for another casting cycle.<br> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtxZ47cC00hVnKOJwXQNM2sLTEd9abesea0jvdUgPiugWYvaondsG0POSXoh6y6X4tkt48a4YSa9fmFveZqPfxj2sWtl_3Qy9vCFzyFPzem2X3atEzUtZfoTh8SVkx0PgtXpUFwGzimeA-/s1600/aluminum+ingots.JPG"><img style="WIDTH: 111px; HEIGHT: 79px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5580002114578685538" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtxZ47cC00hVnKOJwXQNM2sLTEd9abesea0jvdUgPiugWYvaondsG0POSXoh6y6X4tkt48a4YSa9fmFveZqPfxj2sWtl_3Qy9vCFzyFPzem2X3atEzUtZfoTh8SVkx0PgtXpUFwGzimeA-/s200/aluminum+ingots.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTyfm1damhfFVhRdVGTlvDCzwDRL24Xs_9yaHdOumF8o35HfCFC_PjtKIaMl-1HlzWNbvB_zfaakK1Kp-JWOok1S9ZvUsGWkbM5AZo0IfKPJJnTRYplhOd8JfsgKbwlM_sXE_-B4BCI4Pe/s1600/aluminum+sprue+and+riser.JPG"><img style="WIDTH: 120px; HEIGHT: 77px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5580002710380034642" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTyfm1damhfFVhRdVGTlvDCzwDRL24Xs_9yaHdOumF8o35HfCFC_PjtKIaMl-1HlzWNbvB_zfaakK1Kp-JWOok1S9ZvUsGWkbM5AZo0IfKPJJnTRYplhOd8JfsgKbwlM_sXE_-B4BCI4Pe/s200/aluminum+sprue+and+riser.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnfPeayoV8yLCoKR3XR7Fovt-l-kxFN1zHsF066nQViL7sywr9zImRUSX2pprbj6LTBS0MTlJf0JvoCd_nqlxqPJUqp_jRvsnO-BKl5NzgHkFxFAsNxxkxV-uhMRsG9z1v4GQ_tSRFHfrq/s1600/aluminum+eagleC.JPG"><img style="WIDTH: 129px; HEIGHT: 76px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5580002715926874594" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnfPeayoV8yLCoKR3XR7Fovt-l-kxFN1zHsF066nQViL7sywr9zImRUSX2pprbj6LTBS0MTlJf0JvoCd_nqlxqPJUqp_jRvsnO-BKl5NzgHkFxFAsNxxkxV-uhMRsG9z1v4GQ_tSRFHfrq/s200/aluminum+eagleC.JPG" /></a> <Br>The aluminum eagle turned out very well and I am thinking of making a few more :-)<br> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1pzXcmg4uI7xpVes4hSYzG_5ztJ5zLQ4zMg5bb1b-c5QFh3yUxTypao6iFZA1H-f9LdedKgthcsQ3iYWo2uizitgr_iJo7DWnAA1u2QGe0yWq0wp2UwwodRG8Io13y4_fD1ZnN0JuY6TH/s1600/aluminum+eagleD.JPG"><img style="WIDTH: 153px; HEIGHT: 98px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5580003340541793538" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1pzXcmg4uI7xpVes4hSYzG_5ztJ5zLQ4zMg5bb1b-c5QFh3yUxTypao6iFZA1H-f9LdedKgthcsQ3iYWo2uizitgr_iJo7DWnAA1u2QGe0yWq0wp2UwwodRG8Io13y4_fD1ZnN0JuY6TH/s200/aluminum+eagleD.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrfcNUGrJyxCKGNS3plpAQ30PXbVVn_OiLryfvWqgJG_l-3TRPhBid7KUOlJ_DnfQKFR2osjIO57v_RsPAbHu5mRXlbTvTKqhPGmOHsKIuGf94ua029F1x97V3j9uthMLzbUQFtGuDiJuK/s1600/DSCN5088+%2528Small%2529.JPG"><img style="WIDTH: 151px; HEIGHT: 104px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5580692550719216802" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrfcNUGrJyxCKGNS3plpAQ30PXbVVn_OiLryfvWqgJG_l-3TRPhBid7KUOlJ_DnfQKFR2osjIO57v_RsPAbHu5mRXlbTvTKqhPGmOHsKIuGf94ua029F1x97V3j9uthMLzbUQFtGuDiJuK/s200/DSCN5088+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQxfFwrUTwXxk0jZF3su2t6xKH_NX3IA95AXi2G6PMwC1k5oT0Of9viEXlLxIn5ZPe91RKukFuYgQ_-rPquErHr5eQzs8CvDkb61CQ2BukJS8Dsdcl9zZ5CTtUcpaAnAZ9oMtDZFuOwHAy/s1600/aluminun+eagle+back.JPG"><img style="WIDTH: 151px; HEIGHT: 104px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5582392983111903618" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQxfFwrUTwXxk0jZF3su2t6xKH_NX3IA95AXi2G6PMwC1k5oT0Of9viEXlLxIn5ZPe91RKukFuYgQ_-rPquErHr5eQzs8CvDkb61CQ2BukJS8Dsdcl9zZ5CTtUcpaAnAZ9oMtDZFuOwHAy/s200/aluminun+eagle+back.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiic2vfq8fPVycf2LyqxaShMhDqCiDZkoZWotjDHdcpu_d5VvngPBdk-bupbqsUn9ssJuqsAngbDvcZkjXKaz55_GzgDWbHsAP1u7aeUxW3F8sF88UK-K2ZN36-cosnWMoD35F4IJUjKb8i/s1600/DSCN5099+%2528Small%2529.JPG"><img style="WIDTH: 154px; HEIGHT: 104px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5580692551422678130" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiic2vfq8fPVycf2LyqxaShMhDqCiDZkoZWotjDHdcpu_d5VvngPBdk-bupbqsUn9ssJuqsAngbDvcZkjXKaz55_GzgDWbHsAP1u7aeUxW3F8sF88UK-K2ZN36-cosnWMoD35F4IJUjKb8i/s200/DSCN5099+%2528Small%2529.JPG" /></a><br> This is another addition to this post my "flock"of aluminum eagles is getting bigger. I made 3 in 1 flask. Next I started to tap screws on the back of them to secure them to the wall.<br> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYIzL4ESon9Odhj2r04eAMSQYYs2tEFGJtZUeDSZHCX6GLfBR36mj993neaPYtN2xHEeuLm0KT-57hA1T7_xED7JZgv2I8U_T-rwI1qEY1D4lTvIiyoXuj1mGosYjYaGHfonUHQqfWzpIF/s1600/3+aluminum+eagels.JPG"><img style="WIDTH: 137px; HEIGHT: 100px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5583327080331915186" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYIzL4ESon9Odhj2r04eAMSQYYs2tEFGJtZUeDSZHCX6GLfBR36mj993neaPYtN2xHEeuLm0KT-57hA1T7_xED7JZgv2I8U_T-rwI1qEY1D4lTvIiyoXuj1mGosYjYaGHfonUHQqfWzpIF/s200/3+aluminum+eagels.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrlivi3h2nGHYhd4BIR_T3AGiVXFSDPBHMyFFLecTfSIdGaktzBQZF5UFpCF1oT0aBy52sXaoEoXUhX7tudl0PK7LIpCqhlOgpaJ2DaWI47C3rKA-5fHzR-suU3D59Mu_N8AEpFNZz1JWy/s1600/6+aluminum+eagles.JPG"><img style="WIDTH: 127px; HEIGHT: 100px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5583327073899963458" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrlivi3h2nGHYhd4BIR_T3AGiVXFSDPBHMyFFLecTfSIdGaktzBQZF5UFpCF1oT0aBy52sXaoEoXUhX7tudl0PK7LIpCqhlOgpaJ2DaWI47C3rKA-5fHzR-suU3D59Mu_N8AEpFNZz1JWy/s200/6+aluminum+eagles.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSO8bW5D9Cv3cKrcyljXA5UM8HBKrmny1OftfoPFA4fSj9sdsgM9-o6KJd1HAl1Zrf79_Gpi_kuAG8UgUbShrjBzWxMY8JTtPpxpeIJUnjIkIE8hkLhG7ANivAwqT98m7Lb3t5ySSm4l1p/s1600/aluminm+back+screw+tap.JPG"><img style="WIDTH: 125px; HEIGHT: 99px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5583327072892940818" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSO8bW5D9Cv3cKrcyljXA5UM8HBKrmny1OftfoPFA4fSj9sdsgM9-o6KJd1HAl1Zrf79_Gpi_kuAG8UgUbShrjBzWxMY8JTtPpxpeIJUnjIkIE8hkLhG7ANivAwqT98m7Lb3t5ySSm4l1p/s200/aluminm+back+screw+tap.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMLY0KoLvBYdeMovtvq_t3EPFk8-K3CrKlRkvgbOxwlJ36i_KA5razMRDRs7pFw4UL3kWrNo5YmimvEwyP_LiDOzVVdVjaKoDdgmG5sRXTtiK-50B6rj2wLwo1UZ05oPwtI9GiwoaI3gsm/s1600/my+aluminum+eagle+flock.JPG"><img style="WIDTH: 167px; HEIGHT: 99px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5583327078969811650" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMLY0KoLvBYdeMovtvq_t3EPFk8-K3CrKlRkvgbOxwlJ36i_KA5razMRDRs7pFw4UL3kWrNo5YmimvEwyP_LiDOzVVdVjaKoDdgmG5sRXTtiK-50B6rj2wLwo1UZ05oPwtI9GiwoaI3gsm/s200/my+aluminum+eagle+flock.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhl1Qan_5i8UI8I3-aQ2Chyphenhyphen6GX4L41puFMQlKKYy5QtBj3yyq0rPieMb68v9fiVOR7TInYQTGpSQkWWkDjPxv493j6v7cwYMqIVSt_eRZ5nUKGMvg-GIAxpsDtwjvPyKR2ApdrViAurMbG3/s1600/aluminum+eagle+on+wall1.JPG"><img style="WIDTH: 123px; HEIGHT: 68px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5584743527792685602" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhl1Qan_5i8UI8I3-aQ2Chyphenhyphen6GX4L41puFMQlKKYy5QtBj3yyq0rPieMb68v9fiVOR7TInYQTGpSQkWWkDjPxv493j6v7cwYMqIVSt_eRZ5nUKGMvg-GIAxpsDtwjvPyKR2ApdrViAurMbG3/s200/aluminum+eagle+on+wall1.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiixonQg0GdJnlVP7NrkEeP2eIMQbR3XmInpYwuba8zb3bzmfuoTa-2jBZdJWsXe6sfQw0TyD9KzE8WbX5HUDK8i2uj7AfhfRrifQuKlFtvIBVnT_LEXMMeqOWmrfSNk7ugZpaWLd1Fokez/s1600/Daluminum+eagle+on+wall2SCF0512+%2528Small%2529.JPG"><img style="WIDTH: 120px; HEIGHT: 66px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5584743525893941826" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiixonQg0GdJnlVP7NrkEeP2eIMQbR3XmInpYwuba8zb3bzmfuoTa-2jBZdJWsXe6sfQw0TyD9KzE8WbX5HUDK8i2uj7AfhfRrifQuKlFtvIBVnT_LEXMMeqOWmrfSNk7ugZpaWLd1Fokez/s200/Daluminum+eagle+on+wall2SCF0512+%2528Small%2529.JPG" /></a> <br>This casting I made using only one riser and one sprue for two aluminum eagles.<br> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLYO4Fvbx2CEEcQ7qtobsTiRQJTUmNNWU2KcU0W6-kYV9l0OEkgCkIbS_LaDPqcBp8CQgnQbEbzxjBV4S0xLk4KUQplfxzGZXXHrHSOTe8IyIFWWZDjBPvnSP11vLQj6EDT5X_UEiOE7SE/s1600/2+aluminum+eagles+sprue+riser.jpg"><img style="WIDTH: 126px; HEIGHT: 71px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5595901118315328466" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLYO4Fvbx2CEEcQ7qtobsTiRQJTUmNNWU2KcU0W6-kYV9l0OEkgCkIbS_LaDPqcBp8CQgnQbEbzxjBV4S0xLk4KUQplfxzGZXXHrHSOTe8IyIFWWZDjBPvnSP11vLQj6EDT5X_UEiOE7SE/s200/2+aluminum+eagles+sprue+riser.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSOWV3b4aDBWGzfoiR7AWdylrCNoGrLiJEn1Il36HZu97vUOV0j1nEzgRvv6FWcb-lXIqS0x-1snyhTcVdEug-wSHjVXkdEBzhxXDTxUdNnYQ-zhoGP_R9Ns9DK3U_kBZOE7zu1Lqgdz7j/s1600/2+aluminum+eagles+casting.JPG"><img style="WIDTH: 129px; HEIGHT: 73px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5595901115033823602" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSOWV3b4aDBWGzfoiR7AWdylrCNoGrLiJEn1Il36HZu97vUOV0j1nEzgRvv6FWcb-lXIqS0x-1snyhTcVdEug-wSHjVXkdEBzhxXDTxUdNnYQ-zhoGP_R9Ns9DK3U_kBZOE7zu1Lqgdz7j/s200/2+aluminum+eagles+casting.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipOyDSKFr9vBGvj087v6Ut83h8J3vxr6x4AbyQViZmG-dvxNVZ5cHRaC2J34TxNS2C_WkBtuGG1lpMeE6GycNpUUMofL0xKj5lhvO1gAVB7_95RiqJy1st5HaOvwACwBMgOjnD4GNI7TIB/s1600/2+aluminum+eagles+mould.JPG"><img style="WIDTH: 122px; HEIGHT: 74px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5595901112549579058" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipOyDSKFr9vBGvj087v6Ut83h8J3vxr6x4AbyQViZmG-dvxNVZ5cHRaC2J34TxNS2C_WkBtuGG1lpMeE6GycNpUUMofL0xKj5lhvO1gAVB7_95RiqJy1st5HaOvwACwBMgOjnD4GNI7TIB/s200/2+aluminum+eagles+mould.JPG" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-3641566147503536152011-02-25T06:29:00.000-08:002011-02-25T07:26:39.298-08:00Aluminum sun, sand castingThis week I sand casted aluminum sun for my father in law garden.<br /><div><div>I started by making a plaster pattern in a plastic mould. I painted the plaster cast yellow to hang it on the bathroom wall (decorative and could be used as pattern again). After the paint was dry I varnished the plaster cast so it will be easy to remove it out of the petrobond sand.</div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvEIGH4J6D69_xu4M1-ioCXTIJ-DxW_oMgPt2ZLS297A3qUgfGxhdnERKgog99-7cxK3woSIq-vxLcHyeO0Oi2-pr96DpU6ld97t18xpQC1l6ZJRX4MB3NjTSeZ8aEeHvEoKoPIYB6w85d/s1600/sun+plaster+cast.JPG"><img style="WIDTH: 119px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577636966736552626" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvEIGH4J6D69_xu4M1-ioCXTIJ-DxW_oMgPt2ZLS297A3qUgfGxhdnERKgog99-7cxK3woSIq-vxLcHyeO0Oi2-pr96DpU6ld97t18xpQC1l6ZJRX4MB3NjTSeZ8aEeHvEoKoPIYB6w85d/s200/sun+plaster+cast.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2xupOzP-21YXsqRtWFdJ5xRO_ZchSIBIo0WsonGTc9fQgDI5z557XXd9VzimGmi6VLCuny9v13WJUfaiwEyoCRoGtdNID3CV-T2BZlR0c1-sFGAoWaX3G-GE_F8pk_MmRKSduXhw30eEb/s1600/painted+sun.JPG"><img style="WIDTH: 128px; HEIGHT: 83px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577636973596993490" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2xupOzP-21YXsqRtWFdJ5xRO_ZchSIBIo0WsonGTc9fQgDI5z557XXd9VzimGmi6VLCuny9v13WJUfaiwEyoCRoGtdNID3CV-T2BZlR0c1-sFGAoWaX3G-GE_F8pk_MmRKSduXhw30eEb/s200/painted+sun.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0aC6G3P7UcMByWODuQRnRX8YklOlcSp97HZK7WmbFSQ-tB7FjgUf7z1AbxDiAy1EkGJK67ioJ1NKcU8VUIC358PxwgX7kuVNrPKJWlwRVRWa-cyfYVSa_lcKRHFKwuJ2Ux4AUAa2xlZDT/s1600/painted+and+varnished+sun.JPG"><img style="WIDTH: 119px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577636972368501218" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0aC6G3P7UcMByWODuQRnRX8YklOlcSp97HZK7WmbFSQ-tB7FjgUf7z1AbxDiAy1EkGJK67ioJ1NKcU8VUIC358PxwgX7kuVNrPKJWlwRVRWa-cyfYVSa_lcKRHFKwuJ2Ux4AUAa2xlZDT/s200/painted+and+varnished+sun.JPG" /></a><br /></div><div>To get the plaster pattern out of the mould I used 2 screws on the back, The mould was perfect.</div><div>Then I made the sprue and riser on the back of the sun, I predicted there will be some aluminum shrinkage because the amount of molten aluminum used in this casting.</div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiV6nfkV4QmElsgJKwlimy9ZxXP0Tu_5xs6hLJg9Fl8vDPQXI5OhQJ8XqvOwxBUHHBpbn2Qc9OWp_xFYfu74UBQSx-wLQQSBuSydCwHu9ExYBw4ZL5TMD6GEB_UDiCG-jqBpfua2ilzJ4o9/s1600/screws+for+removing+pattern.JPG"><img style="WIDTH: 124px; HEIGHT: 87px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577638001313733906" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiV6nfkV4QmElsgJKwlimy9ZxXP0Tu_5xs6hLJg9Fl8vDPQXI5OhQJ8XqvOwxBUHHBpbn2Qc9OWp_xFYfu74UBQSx-wLQQSBuSydCwHu9ExYBw4ZL5TMD6GEB_UDiCG-jqBpfua2ilzJ4o9/s200/screws+for+removing+pattern.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEig6R3m5Z2mGMn5v8YPy3sfWxuKtkAGYYri7gSmgXYR08xpt1xqDYihECl5V05qDfeufsy_8F_tGDfIBuwaYySiOm0bkaTrkM8bBOogNComtiucgbcoTeazGi6BZzuYLcw4w6O_5eTnkXOT/s1600/DSCN4834+%2528Small%2529.JPG"><img style="WIDTH: 113px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577638867358039378" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEig6R3m5Z2mGMn5v8YPy3sfWxuKtkAGYYri7gSmgXYR08xpt1xqDYihECl5V05qDfeufsy_8F_tGDfIBuwaYySiOm0bkaTrkM8bBOogNComtiucgbcoTeazGi6BZzuYLcw4w6O_5eTnkXOT/s200/DSCN4834+%2528Small%2529.JPG" /></a> </div><div>The pouring part was the easy part I was all most short with the molten aluminum but it was just enough to fill the sprue and riser extension half way up. </div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXjMrvflpZh5uFUXOp3FEXAiT26GUUAp4pSLHri6Oqr2HoP63Uvlroxhymm3aYj8cy49m6E70oygA4noWavfcCJ1hSJDPafofR124RJTPMQnONAM49vK1kgz6ASV-ziWlj3uRMDNfTbIJz/s1600/DSCN4844+%2528Small%2529.JPG"><img style="WIDTH: 131px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577640305415212866" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXjMrvflpZh5uFUXOp3FEXAiT26GUUAp4pSLHri6Oqr2HoP63Uvlroxhymm3aYj8cy49m6E70oygA4noWavfcCJ1hSJDPafofR124RJTPMQnONAM49vK1kgz6ASV-ziWlj3uRMDNfTbIJz/s200/DSCN4844+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1bcqHuPAGF8vCWdi8bj4VPZ6pDqMXSYF8-NbBhS1X1dNxCPIXf6VOtZUs6vBVO4bDd0rT70n_f7BrPCn6XFo3-qqsQHlg-btzzuFRtpgamu8fDP7VKm0jUBqD_I0bqOtZRrQPnFOQsqXl/s1600/DSCN4843+%2528Small%2529.JPG"><img style="WIDTH: 125px; HEIGHT: 84px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577640303111535666" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1bcqHuPAGF8vCWdi8bj4VPZ6pDqMXSYF8-NbBhS1X1dNxCPIXf6VOtZUs6vBVO4bDd0rT70n_f7BrPCn6XFo3-qqsQHlg-btzzuFRtpgamu8fDP7VKm0jUBqD_I0bqOtZRrQPnFOQsqXl/s200/DSCN4843+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjV9zJYnWbpHeVgapyfNn5ewD-xzUnuGt5GiZtGq5BsJDY4UqkQKlLsGpOu0Wx5VCj1B5SpntBt0Jtg49TY7GNMyX0sigaURX_LWe8wODm_kCqQSh1zsrcsLOTn7Z456MUs3rC4mjLYI8wa/s1600/DSCN4845+%2528Small%2529.JPG"><img style="WIDTH: 111px; HEIGHT: 83px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577642416815493826" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjV9zJYnWbpHeVgapyfNn5ewD-xzUnuGt5GiZtGq5BsJDY4UqkQKlLsGpOu0Wx5VCj1B5SpntBt0Jtg49TY7GNMyX0sigaURX_LWe8wODm_kCqQSh1zsrcsLOTn7Z456MUs3rC4mjLYI8wa/s200/DSCN4845+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNIiCTwFyDAjorHlFFQWZ-c4b9ZVTMUF0eq0fxiAyEM-so3VyLt3RmPq2RBilh1jN9rhTLwY7zEnmCo2x9iXr_0MrhVuSrnBWOWA9woVcJKD1zqXhLXCaJeeh3TKJ9zVCEjD-fl3HQTMT_/s1600/DSCN4846+%2528Small%2529.JPG"><img style="WIDTH: 110px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577642151630985346" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNIiCTwFyDAjorHlFFQWZ-c4b9ZVTMUF0eq0fxiAyEM-so3VyLt3RmPq2RBilh1jN9rhTLwY7zEnmCo2x9iXr_0MrhVuSrnBWOWA9woVcJKD1zqXhLXCaJeeh3TKJ9zVCEjD-fl3HQTMT_/s200/DSCN4846+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0hg6Uw6R2ZdW0e42KspzWdkc2lDiZ_tI95gZJ15Wz9txvkLM8u6Vww3CuEThKIgWSGpzEoUOztFVZ5jl34qDFotmSmWS8psb4BbrzeStbn_lLKxwEGVGnfLVjkgAHD6oj_S1mRaW_mOdG/s1600/DSCN4847+%2528Small%2529.JPG"><img style="WIDTH: 116px; HEIGHT: 81px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577642817663356178" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0hg6Uw6R2ZdW0e42KspzWdkc2lDiZ_tI95gZJ15Wz9txvkLM8u6Vww3CuEThKIgWSGpzEoUOztFVZ5jl34qDFotmSmWS8psb4BbrzeStbn_lLKxwEGVGnfLVjkgAHD6oj_S1mRaW_mOdG/s200/DSCN4847+%2528Small%2529.JPG" /></a> </div><div>The sun casting turned out very well, some shrinkage on the back because the lack of aluminum to feed the mould. You can see in the image that the sprue and riser extension did their part. The only thing left to do was to cut off the sprue and riser with a grinder make two holes for screws and hang it on the wall.</div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiY801Rc1P2EqURpygkS_VR7IvBwMTgDloeHw1oBZaJahNw-KNzqwi9M2pHAyizpryC46sW8dTEa95HmI6FdC8GtpiU8F9zB4a39br6BWZNMeOkv-3yUrWqGZvbW-JkXUtr2rJHwaw3ZIOF/s1600/DSCN4868+%2528Small%2529.JPG"><img style="WIDTH: 112px; HEIGHT: 88px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577645717298201346" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiY801Rc1P2EqURpygkS_VR7IvBwMTgDloeHw1oBZaJahNw-KNzqwi9M2pHAyizpryC46sW8dTEa95HmI6FdC8GtpiU8F9zB4a39br6BWZNMeOkv-3yUrWqGZvbW-JkXUtr2rJHwaw3ZIOF/s200/DSCN4868+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhk1wjGgiqkX5XfY8JhPOfy6BWBMpfXvTh0QEfBuzYrQcZ53L1lIs6Z4uRGYix8w0d9ppdKH7dTgdTHKi8DhWIQCS1xQWvhZy-oSAvT1Cm07dYKM4DYRln2s9RxXEVm_gm-IR2WgWu6kZns/s1600/DSCN4871+%2528Small%2529.JPG"><img style="WIDTH: 114px; HEIGHT: 88px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577644752379469410" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhk1wjGgiqkX5XfY8JhPOfy6BWBMpfXvTh0QEfBuzYrQcZ53L1lIs6Z4uRGYix8w0d9ppdKH7dTgdTHKi8DhWIQCS1xQWvhZy-oSAvT1Cm07dYKM4DYRln2s9RxXEVm_gm-IR2WgWu6kZns/s200/DSCN4871+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3vHAyB78bEEp48qT-mK5i8kXrro4In5iNUER1CZKNcTHEns5MFRQazuLCc8amBsRxJCHMVcr7j8KzPupyHvvzHo8IYUnteJFdesMQAna0cr2JoUFjOjLzDXtqp5Uwi5n0iE3TR4y2meF8/s1600/DSCN4890+%2528Small%2529.jpg"><img style="WIDTH: 107px; HEIGHT: 88px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577645396180419986" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3vHAyB78bEEp48qT-mK5i8kXrro4In5iNUER1CZKNcTHEns5MFRQazuLCc8amBsRxJCHMVcr7j8KzPupyHvvzHo8IYUnteJFdesMQAna0cr2JoUFjOjLzDXtqp5Uwi5n0iE3TR4y2meF8/s200/DSCN4890+%2528Small%2529.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixJfI3XtPbtPpvvb830gIWZvTNUevgwEUc-JzP0ory_QHiFrdbck3JsL4r2B6wPLFbxOCU847JCnCSjUBhD6P0gZzJcJDLJI8GRaSNEhK0pCG8HsjhP3RQ4V-UYql0704iy7lPQlo-3Pcv/s1600/DSCN4924+%2528Small%2529.JPG"><img style="WIDTH: 120px; HEIGHT: 87px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577644757936647602" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixJfI3XtPbtPpvvb830gIWZvTNUevgwEUc-JzP0ory_QHiFrdbck3JsL4r2B6wPLFbxOCU847JCnCSjUBhD6P0gZzJcJDLJI8GRaSNEhK0pCG8HsjhP3RQ4V-UYql0704iy7lPQlo-3Pcv/s200/DSCN4924+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDIhUoG4N18S-46ESdt5IrlPUyvHPtqC8tCZsNh-AFBzKr_0sdwnhFdBHmtcWIIa60wUBJ-RMepyQX_NXZi1VcabVVo3Y5pnyXFllNZPMLXZ3t9kmUCZu9OvRAU614CB728qLFqQjQACkG/s1600/DSCN4931+%2528Small%2529.JPG"><img style="WIDTH: 116px; HEIGHT: 87px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577644757376986530" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDIhUoG4N18S-46ESdt5IrlPUyvHPtqC8tCZsNh-AFBzKr_0sdwnhFdBHmtcWIIa60wUBJ-RMepyQX_NXZi1VcabVVo3Y5pnyXFllNZPMLXZ3t9kmUCZu9OvRAU614CB728qLFqQjQACkG/s200/DSCN4931+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDsvdLuV9W3maEQuhZ0Qhat172yqA4oORWZVK_H1YPSd9AqLzTHpSi8tubWDiY_NzmYZkY3aTi7OP-k82DL0ABNuvHJxxBzo5p6WrNzgKopkpibUwbpu6mIEDcYudEHLw4SSes5vRWuciC/s1600/DSCN4889+%2528Small%2529.JPG"><img style="WIDTH: 117px; HEIGHT: 88px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5577644758206013010" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDsvdLuV9W3maEQuhZ0Qhat172yqA4oORWZVK_H1YPSd9AqLzTHpSi8tubWDiY_NzmYZkY3aTi7OP-k82DL0ABNuvHJxxBzo5p6WrNzgKopkpibUwbpu6mIEDcYudEHLw4SSes5vRWuciC/s200/DSCN4889+%2528Small%2529.JPG" /></a> </div></div>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-12787658326036937152011-02-17T14:53:00.000-08:002013-08-07T14:02:49.169-07:00Sand Casting Terminology<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqxZZiGPejKbzwT1bfa6LO9pu-BbxFLtTvQVKSzXHGF9JPDcHEdmlMTfFD2ZOnBLxYN_MuzkB9pKLjaC7up8NutKHvBUK3iKJYxiNByoqh6Xk1_VBdcIu8PSK43A2kAIhmX_2UfHLYKPW9/s800/furnace.JPG" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img height="130" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXARIfLJ7z3HHDn4F0iINBhYe_iciBNNsa5Z1unXcmMILWoWZFsKB4C5iq9Rt5ZeIJEYNKA9gqElKPdQgNkeA3jwWNWCFaV-2-fXlPUlYfUa-jKCz6ULQCJOYABGe91IFhl36ozO8CBXq1/s144/furnace.JPG" style="height: 49px; width: 51px;" width="144" /></a><b><u>Furnace</u>:</b> <span id="goog_1020556814"></span><span id="goog_1020556815"></span><a href="http://www.blogger.com/"></a> A furnace is a device used for heating. The name derives from Latin fornax. In my blog I will introduce my home made furnace for melting aluminum. In order to Heat this DIY type of furnace it could be achieved by using charcoal, propane gas, waste oil or electric heating element.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHaiHHmBJRspq5zmVCE51yAYTv_rZ2YRklfG7WHBe_Djm9xkImka0_nEYVxHBVlxCunFEe2qELKEbmwOwJt7bLB1j3ditBQU38_k2IUogKWdbXTRYUPgHVX7N-smO2P2NQRXjx_83S-e9m/s800/crucible.jpg" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img height="144" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxqz50UE9T7afybQ1s-8tFlLgiuisQnoNOBA4APYOLLaW7BaDXPVZwble6MwUtZ323wBpgTqs1R2LVbl1_eMKJLFSc0f9Ne08Uw06vgsgkMy-RlPoEUZKtoWyOJO8NKAdzg6riUgY-joqE/s144/crucible.jpg" style="height: 42px; width: 31px;" width="115" /></a> <u><b>Crucible:</b></u> Is the container that holds all the aluminum parts to be melted. There are different types and sizes of crucibles that can be bought online some are relatively cheap. The most common one is the Graphite crucible. Another way is making your own crucible by using a 8mm thick steel pipe and to weld a 5mm metal base plate.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiua60cthaT6cWob8nr27XIf9ajzJkrm7scJCRbRMoHtqQAu2tUR62LkHgqBetnVsKnLqa_ile3rn99KKYuZ43mNL4b_eW5aRjJIyj2PgdZWCVJVEhV9h0-Uif78mwPZP1TdFKepc2icEFb/s800/Dross.JPG" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img height="112" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3ZrTWXE-lFq0r-eIcTFBiOd2FU4TWF2lOMAjwUUbcctMT6cKHP-PkyIgz_gl5T2rKa7FFxYqNnsH2rcct7yCUdOk55B3oXU2mJKiIlIkU6mroUTfNd4ky3Nx4J4b2102veQ317IuDyacK/s144/Dross.JPG" style="height: 35px; width: 56px;" width="144" /></a> <b><u>Dross/slag</u>:</b> When the aluminum melts at 660°c most of the impurities such as paint will float on the top of molten aluminum and will have to be skimmed off before pouring the molten metal.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSP2GOZz9XB1vLCd4MTbwTB8HqRJNLAcWMPv7to54P03K1n73-MksE_LguMHwNpG9scrbsIiOPDYvsZQMRizxH-VkmkuYAIOy_j_7d-DZwYBHdfrvoxmHCxQHIjzY3m5f2ktVm8GfOR7lY/s800/refractory.JPG" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img height="124" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-FczKYPQD1E9feJyr_fqxFBbh47PvDo0uoLOBbPziN9xKNyHaYYdOCpBZfLzJ5bGZya2FBI4ZBjV1kxS4lFF2HmsJtlF7FAbFii9zsEcOThcqO14N_iFi1Hn34fbSsKhB60g2ePVMOCGT/s144/refractory.JPG" style="height: 44px; width: 52px;" width="144" /></a><u><b>Refractory</b></u>: The material inside the furnace that retains the heat and has to provide a good insulation inside the furnace. The refractory could be home made and there are many sites that provide info regarding the "ingredients" and ratio of mixing. Some hardware shops sell bags of ready mix refractory.<br />
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<u><strong></strong></u><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgH-zF0KAUv2RwyqkX9s2z-kUOc0ZLHY1BI2b3PYYmb7kjCv-2W1iR6VBIRFGZVQUy5k6YQBYv9ZILM9vOU2hRrnfSAw2lbbfyAsLfKvskdfvCmaULBP1yNYadf321JrwAF0SeOWGSg2S_b/s1600/Flask_cope_drag.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5541974817362224322" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgH-zF0KAUv2RwyqkX9s2z-kUOc0ZLHY1BI2b3PYYmb7kjCv-2W1iR6VBIRFGZVQUy5k6YQBYv9ZILM9vOU2hRrnfSAw2lbbfyAsLfKvskdfvCmaULBP1yNYadf321JrwAF0SeOWGSg2S_b/s200/Flask_cope_drag.JPG" style="height: 57px; width: 88px;" /></a><strong><span style="color: #000066;"><u>Flask:</u></span></strong> This is the container box that holds the molding sand. The box is opened from the top and the bottom and could be created in any shape and size. Most simple flasks contain two parts. Most flasks are made of alumimum, steel or wood and have different types of aligning "systems" such as pins or just timber parts aligining the cope and drag to the same position. For more commercial and multi use of your flask hinges could be added to the flask parts in order to take the flask off and use it for another molding. It is optional to add ribs inside the flask for a better sand grip.<br />
<u><strong><span style="color: #000066;">Cope:</span></strong></u> Is the top part of the flask.<br />
<u><strong><span style="color: #000066;">Drag:</span></strong></u> Is the bottom part of the flask.<br />
<u>I made this simple sketch showing most parts of a basic sand casting structure:</u><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZzJBc37rXMbm1NA7NQa8XpSs4haLJH53Zaejllqm-BveYd6VvlueecqEpWgmnuZIQQNGKYVYPN0OI99bgq_-QnaHS4ug0pzY0TsvqIh6ZVFkIFKJIsG65KjR8wRqp-IhCyu7CoZvDINOU/s1600/casting+sand+flask+sketch.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5574767889898304162" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZzJBc37rXMbm1NA7NQa8XpSs4haLJH53Zaejllqm-BveYd6VvlueecqEpWgmnuZIQQNGKYVYPN0OI99bgq_-QnaHS4ug0pzY0TsvqIh6ZVFkIFKJIsG65KjR8wRqp-IhCyu7CoZvDINOU/s200/casting+sand+flask+sketch.JPG" style="cursor: hand; height: 85px; width: 200px;" /></a> <br />
<u><strong><span style="color: #000066;">Parting line:</span></strong></u> Is the line where the drag and cope meet.<br />
<u><strong><span style="color: #000066;">Pouring cap/basin:</span></strong></u> This is the hole on top of the cope part made to pour the molten aluminum into the flask.<br />
<u><strong><span style="color: #000066;">Gas vent:</span></strong></u> This is so when pouring the molten metal the gas will escape from the vent. A gas vent can be easily made using a straight wire.<br />
<strong><span style="color: #000066;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTyfm1damhfFVhRdVGTlvDCzwDRL24Xs_9yaHdOumF8o35HfCFC_PjtKIaMl-1HlzWNbvB_zfaakK1Kp-JWOok1S9ZvUsGWkbM5AZo0IfKPJJnTRYplhOd8JfsgKbwlM_sXE_-B4BCI4Pe/s1600/aluminum+sprue+and+riser.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5580329453629703314" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidLISAT67jb4Vybyh1bkGbBH2gL_klUC626YgICseT_0vYP8xrTCsTd3W8U8tJJjtjnycV_6n6dqNYpIOAy95V7YXlWhiGv09YWrCWKOxlBA70cNnoH_ufwsO0zV1TdK2ASytQtBLee82Y/s200/aluminum+sprue+and+riser.JPG" style="cursor: hand; height: 52px; width: 79px;" /></a> <u>Riser:</u></span></strong> The riser will feed more molten metal into the cavity mould when shrinking accurse.<br />
<u><strong><span style="color: #000066;">Sprue:</span></strong></u> This is under the pouring cup connected to the runner channeling the molten metal into the mould cavity.<br />
<u><strong><span style="color: #000066;">Runner:</span></strong></u> The horizental channel feeding the molten metal into the mould cavity.<br />
<u><strong><span style="color: #000066;">Mould Cavity:</span></strong></u> This is where all the molten metal sets creating a duplicate of the pattern.<br />
<u><strong><span style="color: #000066;"><a href="http://www.flamingfurnace.com/2010/10/aluminum-sand-rammer.html"><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZpKgbNgyDsoiFilQeEUUogsiBpE_qpbpc16U-A10I65CP41X2WeS3DkaoEEMaoxzIrjC2BRdyc_oV0mjYn5IOOO7zqQp2JTsw52U9HTbjSSUMy6qPVTj4vLYSSEudhjdRhwuLrkbpBe9p/s200/DSCN3297+(Small).JPG" style="cursor: hand; height: 52px; width: 74px;" />Pattern:</a></span></strong></u><span style="font-size: 0;"></span>Any objects placed in the casting sand creating an impression of the pattern to be created. A pattern could be made from steel, wood, plastic and other materials.<br />
<u><strong><span style="color: #000066;"><a href="http://www.flamingfurnace.com/2011/11/green-casting-sand-vs-oil-bonded-sand.html"><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHTsMoTxcy8uSCadfmYJ6AHegU77vjKy6eRwus2IjKFPr5wPMPEPl52Q9I5HVqENhO8SWRx0bOMGO8iiqW5luaJNQsBpdFTD9i6UzF0n-6sPkxWXuFz3Mqbv4bSsa2ToPbd_F3v8L7exfV/s200/green+sand+2.jpg" style="cursor: hand; height: 64px; width: 113px;" />Green Casting Sand:</a></span> </strong></u><br />
Green sand is an aggregate of sand, (not green in color). Green sand is combined of very fine sand such as silica, olivine or even play sand mixed with bentonite clay and water. There are many recipes that can be found on the internet for the different types and quantities and mixing ratio. Adding to much water can lead to "porosity", casting defects as result of gas bubbles accouring while pouring the molten metal. Some metal casters use blow torches (heat-dry) over the finished moulded sand to achieve a more rigid mould. Making a good mix of green sand is a much cheaper solution then buying a ready mix.<br />
<strong><span style="color: #000066;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX6aC5KAEtaixeubz8_0YEKn-hUqTIwRdqCE1IdAMp5miAN90_ST7uDOUho20YeZEfEOVKP1Ju-s3sp39lkfowmeocDhd4wLSZPoz4QBRu1wifJM_9dyOKfU1dG02MVYnSnn4CZjWn4T6m/s1600/petrobond.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5574975760462560562" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX6aC5KAEtaixeubz8_0YEKn-hUqTIwRdqCE1IdAMp5miAN90_ST7uDOUho20YeZEfEOVKP1Ju-s3sp39lkfowmeocDhd4wLSZPoz4QBRu1wifJM_9dyOKfU1dG02MVYnSnn4CZjWn4T6m/s200/petrobond.JPG" style="cursor: hand; height: 85px; width: 77px;" /></a> <u>Oil Bonded Casting Sand:</u></span> </strong>This type of sand could be bought as ready made. The sand is very good for high detail mouldings and is easy to work with. It's less likely to get high percentage of porosity because this type of sand is oil bonded and NOT mixed with water. The down side is it's expensive and burnt sand smoke is not the best to inhale. I personally use petrobond and am amazed everytime at how easy it is to work with and the great results after every aluminum casting.<br />
<strong><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi_4t-MbbEAtZWEP7eER9Tr-ZOxScV8vWe0ogbuyd4J7hjPCNFvsYj9f7CLYWpBecWRPvBxiDRGRbvQg6sqs6AOK1gXRlryeSJqxXy74OErYIpATqEcGVA4izZMh9OvY1mug1OM8-1osiu/s1600/sand+muller.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5574771163954716002" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi_4t-MbbEAtZWEP7eER9Tr-ZOxScV8vWe0ogbuyd4J7hjPCNFvsYj9f7CLYWpBecWRPvBxiDRGRbvQg6sqs6AOK1gXRlryeSJqxXy74OErYIpATqEcGVA4izZMh9OvY1mug1OM8-1osiu/s200/sand+muller.jpg" style="cursor: hand; height: 63px; width: 78px;" /></a> <u><span style="color: #000066;">Sand Muller:</span></u> </strong>Mixing big quantities of sand by hand is quit a task and for that there is a great invention called a Sand Muller. The muller is a clean way of mixing the sand without getting unwanted contaminators into the sand and saving a lot of hard labour time. The muller mixes the sand, clay and water with its crushing wheels. There are many websites of homemade designes of big and small mullers whatever suits your needs just google "sand muller".<br />
<strong><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZd2tTu7RGbGIJbOuTAfsAyhrPrsTFlLqI3obQShMs75bDWiFtSKIMlgg4btHWodYtFdiZkQ6oxsprwjwUCiP4vQDosDkQDUDFNSWCDCinxrP62IrMsri_YWlcZNmclbW7wdEl_pzKDq0c/s1600/foam+casting.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5574769196359706546" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZd2tTu7RGbGIJbOuTAfsAyhrPrsTFlLqI3obQShMs75bDWiFtSKIMlgg4btHWodYtFdiZkQ6oxsprwjwUCiP4vQDosDkQDUDFNSWCDCinxrP62IrMsri_YWlcZNmclbW7wdEl_pzKDq0c/s200/foam+casting.jpg" style="cursor: hand; height: 49px; width: 113px;" /></a><u><span style="color: #000066;">Lost Foam Casting:</span></u> </strong>Another option of sand casting is to make a foam pattern with Polystyrene or styrofoam. The pattern dissolves when pouring the molten metal forming the desired object. The mould pattern can be easily carved out or cut with a <strong>hot wire Foam Cutter, </strong>the cutter could be made DIY or you can buy one. Molded foam is a cost effective solution. Burning foam fumes can be toxic <strong><span style="color: #000099;"><u>always wear a respirator and work in a well ventilated area.</u> </span></strong><br />
<u><strong><span style="color: #000066;">Sand casting tools:</span></strong></u> When working with casting sand the caster needs a few basic tools to achieve good casting results. Casting tools can be expensive, the hobby metal caster can use home objects or tools which are as good as professionals ones.<br />
<u><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglC9ov407lQ7o8tzfW6Mk5gICMj3UO1lmm4AJdDp_RNmB_wFyM1qIHvSJkZEdvfmYJYU5NkKjTLZ2hyphenhyphenzHBpKX_P3X8P9rxvRj6aisOkL70QZxprc1ii_KV9fg-qGu5sxoQHJMhvzYu31fL/s1600/DSCN3443+(Small).JPG"><strong><img alt="" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglC9ov407lQ7o8tzfW6Mk5gICMj3UO1lmm4AJdDp_RNmB_wFyM1qIHvSJkZEdvfmYJYU5NkKjTLZ2hyphenhyphenzHBpKX_P3X8P9rxvRj6aisOkL70QZxprc1ii_KV9fg-qGu5sxoQHJMhvzYu31fL/s1600/DSCN3443+(Small).JPG" style="cursor: hand; height: 51px; width: 61px;" /></strong></a><strong><span style="color: #000066;">Sand Rammer:</span></strong></u> this is used to pack all the sand into the flask eliminating air pockets and lose sand that might ruin the final mould after pouring the molten metal. The rammer comes in different sizes. Most rammers are <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZpKgbNgyDsoiFilQeEUUogsiBpE_qpbpc16U-A10I65CP41X2WeS3DkaoEEMaoxzIrjC2BRdyc_oV0mjYn5IOOO7zqQp2JTsw52U9HTbjSSUMy6qPVTj4vLYSSEudhjdRhwuLrkbpBe9p/s1600/DSCN3297+(Small).JPG">made of wood or aluminum, one side flat the other side narrow to fit into the flask corners</a>. For bigger jobs and more commercial use the electric hand rammer is ideal. If one does not have a sand rammer a simple block of timber will do to pack the sand well into the flask.<br />
<u><strong><span style="color: #000066;">Metal wire:</span></strong></u> can be used to create the gas vent holes.<br />
<u><strong><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSBRV4CiwNxRwYvaWfkmHlTW-qpVVX4elzHpf-evnry0A6hQ7n_7QKaqEoCOEZXJ-wAzTnexvPdXhPcotgmp_G5EVnPHitO42O92Ac_zd9iCOJAzJrvt6JRMGXCFzTqynftiilFBAtFxPh/s1600/DSCN3379+(Small).JPG"><img height="354" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSBRV4CiwNxRwYvaWfkmHlTW-qpVVX4elzHpf-evnry0A6hQ7n_7QKaqEoCOEZXJ-wAzTnexvPdXhPcotgmp_G5EVnPHitO42O92Ac_zd9iCOJAzJrvt6JRMGXCFzTqynftiilFBAtFxPh/s1600/DSCN3379+(Small).JPG" style="height: 39px; width: 69px;" width="359" /></a><span style="color: #000066;">Strike off bar:</span></strong></u> is used to strike all the extra sand from the flask top or bottom. I for example used L-shaped metal angle for leveling.<br />
<u><strong><span style="color: #000066;">Molder Trowel:</span></strong></u> could be replaced with a pointy block layer finishing trowel.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNasWoDLd6Cwm9cCdAkuuD_PLJLFS00dSkGIaTUjqizVHgAJffulKlbGQfd4l6mxM2OKdm-8V_10fPGGUFQYXXNyuoGe-jViXbbmsKLa61jXV-kUkzQXKgU3TT9_KPQdkr4ltW8HhNfOb7/s1600/DSCN3382+(Small).JPG"><img height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNasWoDLd6Cwm9cCdAkuuD_PLJLFS00dSkGIaTUjqizVHgAJffulKlbGQfd4l6mxM2OKdm-8V_10fPGGUFQYXXNyuoGe-jViXbbmsKLa61jXV-kUkzQXKgU3TT9_KPQdkr4ltW8HhNfOb7/s1600/DSCN3382+(Small).JPG" style="height: 39px; width: 72px;" width="284" /></a><u><strong><span style="color: #000066;">Slick:</span></strong></u> this could be replaced with a simple small kitchen spoon to create for example the pouring basin or runner or to clear off unwanted sand particles etc'.<br />
<strong><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhA7SAKGoOpIGPIJ3nsN3CutX42CL1i2KUd_16mtzednGd0vRnmtU78n9Qy_uBzVsKbc2ktspvvxCVn4R4Hul4LBebBxcUn5JpW6rVYvjmPrsnoRtWUgZUMRezR4RVndL_T5_9vCTTc21tR/s1600/sifting+mesh.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5571259008782625314" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhA7SAKGoOpIGPIJ3nsN3CutX42CL1i2KUd_16mtzednGd0vRnmtU78n9Qy_uBzVsKbc2ktspvvxCVn4R4Hul4LBebBxcUn5JpW6rVYvjmPrsnoRtWUgZUMRezR4RVndL_T5_9vCTTc21tR/s200/sifting+mesh.JPG" style="cursor: hand; height: 40px; width: 65px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKz7SMm8twfeHnmHK1ihUOYW-dCrILnT5wurhPmXI56nF47HlkQFcWV199Tsy2_tyU2prHlWJrmZ-hsRE8lH9UwrRvj90iDyLKlHxjlwSn1Cl5LK9DDMMBMWbBuEX6hG0tbzKZ8qGzC2xd/s1600/sifting+sand.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5571259008928182738" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKz7SMm8twfeHnmHK1ihUOYW-dCrILnT5wurhPmXI56nF47HlkQFcWV199Tsy2_tyU2prHlWJrmZ-hsRE8lH9UwrRvj90iDyLKlHxjlwSn1Cl5LK9DDMMBMWbBuEX6hG0tbzKZ8qGzC2xd/s200/sifting+sand.JPG" style="cursor: hand; height: 40px; width: 65px;" /></a><u> <span style="color: #000066;">Sand Sifter:</span></u></strong> A sifting tool is used for spreading very fine textured sand directly into contact with the pattern to get the best finishing results. Mesh size will determine how fine sand grain is sifted. I used a simple garden mesh with a deep wooden frame to prevent sand falling out of the sifting mesh.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKm02tY92G1Ws7ZzVOff77lphBcJlaGjwAN_v5OIptB2KRphGN1aCy4xZYLu9dGzlL918MfvJc0AyCYNMNLQk63a9mWp_Tzh7xjwkN7Yvi5btFoba6kzIh2oJ4G4q5E0ZD_MgrZ87kdiP1/s1600/DSCN3260+(Small).JPG"><img height="381" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKm02tY92G1Ws7ZzVOff77lphBcJlaGjwAN_v5OIptB2KRphGN1aCy4xZYLu9dGzlL918MfvJc0AyCYNMNLQk63a9mWp_Tzh7xjwkN7Yvi5btFoba6kzIh2oJ4G4q5E0ZD_MgrZ87kdiP1/s1600/DSCN3260+(Small).JPG" style="height: 39px; width: 74px;" width="289" /></a> <u><strong><span style="color: #000066;">Parting Powder:</span></strong></u> is used to release cope from drag and over pattern preventing the molding sand from sticking and ruin the mould finshing. Talc powder can be used too and will be as effective.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4XDU02Ilc-8JBbm5In9e0qPR028vrHdTgeHsF-QgEVLdJvTcv-Pbr1F5cZbeIOGRYL-Bv4v1R834iKrdM6FATamsUKDPzJny5gM5F1Pa0xOO9bXphpLhxUtNp8U1rXKQGmLu3-ldnFidw/s1600/DSCN3455+(Small).JPG"><img height="297" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4XDU02Ilc-8JBbm5In9e0qPR028vrHdTgeHsF-QgEVLdJvTcv-Pbr1F5cZbeIOGRYL-Bv4v1R834iKrdM6FATamsUKDPzJny5gM5F1Pa0xOO9bXphpLhxUtNp8U1rXKQGmLu3-ldnFidw/s1600/DSCN3455+(Small).JPG" style="height: 40px; width: 65px;" width="181" /> </a><u><strong><span style="color: #000066;">Sprue and Riser:</span></strong></u> To create the Sprue and Riser can be done simply by cutting timber to fit the work flask. For example I used a rounded timber toy to create the Sprue adding the casting sand around it.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzZiq63UnF95rfD3uYkEfSr0CQdzMvR71Wcy4X-sQUeTBNI6gFJTz3JKc70APNIPtit3J0fpsPaSIzQb3566Mbk7OX5Bd_fCvqAYl_ZmCwWor0OAMX_MflT0itRqIcMZmD_Am4U5uzDaWi/s1600/creating+sprue+and+riser.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5571267152057387474" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzZiq63UnF95rfD3uYkEfSr0CQdzMvR71Wcy4X-sQUeTBNI6gFJTz3JKc70APNIPtit3J0fpsPaSIzQb3566Mbk7OX5Bd_fCvqAYl_ZmCwWor0OAMX_MflT0itRqIcMZmD_Am4U5uzDaWi/s200/creating+sprue+and+riser.jpg" style="cursor: hand; height: 40px; width: 65px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgh1lNP-19NsqjWf5dS1LjTULatma92s-Ewu-YOqAGjJvN8f1k85t8etpaM5UPPuJIrXSx0UTHUWmVO1J5RVL3h0FCzliVooGv_mtdX6d7xcfbNI-S-8d3W6uMjLuMKdXprywUnK2O26Nrq/s1600/aluminum+feeder+extension.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5571267150074493682" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgh1lNP-19NsqjWf5dS1LjTULatma92s-Ewu-YOqAGjJvN8f1k85t8etpaM5UPPuJIrXSx0UTHUWmVO1J5RVL3h0FCzliVooGv_mtdX6d7xcfbNI-S-8d3W6uMjLuMKdXprywUnK2O26Nrq/s200/aluminum+feeder+extension.JPG" style="cursor: hand; height: 40px; width: 65px;" /></a> Another option and I think it is better is to use a hollow metal tube to make the sprue and riser by pushing the tube into the sand at the correct location. The metal tube should be of very small thickness which makes pushing it into the sand very easy without breaking the sand.<br />
<strong><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbv7Bseld_fXokODjNyrvmRXaX2Dx5nLA56Sh1TPDds_Sr1u8n0sju6AOx4OEX4b5YtYmK86aPVPt6LyGsToKXLqtEOhQOMVmTbYEs9Ix_2kB5Ab-yKRLKSJamgkhVG35pu_xq1T38ZiMr/s1600/molten+aluminum+feedr.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5574790452535936978" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbv7Bseld_fXokODjNyrvmRXaX2Dx5nLA56Sh1TPDds_Sr1u8n0sju6AOx4OEX4b5YtYmK86aPVPt6LyGsToKXLqtEOhQOMVmTbYEs9Ix_2kB5Ab-yKRLKSJamgkhVG35pu_xq1T38ZiMr/s200/molten+aluminum+feedr.JPG" style="cursor: hand; height: 60px; width: 87px;" /></a><u> </u><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmGiKh1bw5QfPlFc2Ute2s8_8bo2JUW-tTMx922IjaD4vm2OTKp33ecgU5YzRCPQsQn6Q8DZEFOqYcInjOj5m_gAnATYwPYcMT1EH8MuRe3hkGFvOV7ej2ULhVa5OresbOufGh89dd45iC/s1600/riser+feeding+aluminum.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5574790447689875362" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmGiKh1bw5QfPlFc2Ute2s8_8bo2JUW-tTMx922IjaD4vm2OTKp33ecgU5YzRCPQsQn6Q8DZEFOqYcInjOj5m_gAnATYwPYcMT1EH8MuRe3hkGFvOV7ej2ULhVa5OresbOufGh89dd45iC/s200/riser+feeding+aluminum.JPG" style="cursor: hand; height: 59px; width: 81px;" /></a> <u><span style="color: #000066;">Sprue and riser extension:</span></u></strong><span style="color: #000066;"><br />
</span>This is optional and has two purposes. First one is to pravent spilling molten metal all over the flask top. If you are working with wood flasks this will pronlong their lives. Second the sprue and riser extension will act as a pressure head, feeding molten metal into the casting and limiting the aluminum shrinkage. (see image of the <a href="http://flamingfurnace.blogspot.com/2010/12/sand-casting-aluminum-handle.html">aluminum handle</a> I made).<br />
Here is an example of a perfect casting I made as a base for an object. In the image you can see all the parts as I took it out of the casting sand. The mould was made with a sprue feeder, open riser and a molten metal well. The casting is perfect with ZERO defects.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghI6Fw-AurqLy84wXgDmoOIKevFdm_3j-rhvnTCkCkBUCe91_H65Ndk48WBK5pgeMK4t1-7ZpZnipqbhcPyJJTSNa4gXyce50V8qb64Lrzb2ZJLDZrwa6obwVIpgV-Gu4oWXFm3l67xm2p/s1600/aluminum+casting+parts.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5574773327161118418" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghI6Fw-AurqLy84wXgDmoOIKevFdm_3j-rhvnTCkCkBUCe91_H65Ndk48WBK5pgeMK4t1-7ZpZnipqbhcPyJJTSNa4gXyce50V8qb64Lrzb2ZJLDZrwa6obwVIpgV-Gu4oWXFm3l67xm2p/s200/aluminum+casting+parts.JPG" style="cursor: hand; height: 79px; width: 116px;" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-5019652236581061072011-01-24T12:12:00.000-08:002011-02-08T14:27:10.576-08:00Aluminum ingots for the foundryIn this post I will focus on the making of aluminum ingots. The process of making the ingots is very simple all you need is a metal container that will hold the molten metal and will not break under the high temperature. After the aluminum is melted in the crucible and all dross is skimmed off it is ready to be poured into the metal container. I personally don't mix between the aluminum alloys only if they are from the same source of aluminum. I mark every ingot what his origin alloy is from.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR9X8eBzS_397bED4WOMIUCfw89ih_jHqe7Egy_X-XhqA1dATHTjWinmGAQe0VWvAHZr9OgbbZ_qElykcC9tCET2ENX5YWKGbMofoe24PbjN4df5iYsG3CqNQoYLV-KpfBkB6OmyawIIAg/"><img style="WIDTH: 171px; HEIGHT: 77px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566530162340887330" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR9X8eBzS_397bED4WOMIUCfw89ih_jHqe7Egy_X-XhqA1dATHTjWinmGAQe0VWvAHZr9OgbbZ_qElykcC9tCET2ENX5YWKGbMofoe24PbjN4df5iYsG3CqNQoYLV-KpfBkB6OmyawIIAg/s200/aluminum+ingots.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMS8SZT_2FHgSIvzvrab9ogFPrWvFsYMHRtEcIpnKhord3Nqqf_5in2IkhznrzNfMdjdJnn58j4Pi3vLd-u45KYt6vRoN1upj2etS2Bw482bykkgUjfLRneIh5-bbImU5BJUM66ytlhfNx/s1600/molten+aluminum.JPG"><img style="WIDTH: 95px; HEIGHT: 79px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566534144371939874" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMS8SZT_2FHgSIvzvrab9ogFPrWvFsYMHRtEcIpnKhord3Nqqf_5in2IkhznrzNfMdjdJnn58j4Pi3vLd-u45KYt6vRoN1upj2etS2Bw482bykkgUjfLRneIh5-bbImU5BJUM66ytlhfNx/s200/molten+aluminum.JPG" /></a><br />As for the ingot container any metal container is good depending how big you want the ingot to be, don't forget it has to be fitted into the crucible.<br />Big aluminum parts could be broken with a heavy hammer so they will fit into the crucible. Another option is heating the aluminum parts in an open fire until the aluminum is soft enough to be broken easily.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiACEYRcDw5JhDtVw3YA0iwRVMe2fqMs6t2p8J9bg0-H1ZyjmbJqQw03OiAChD0Ty9Us8BultYt9blgOz_L32gSiJUakQ4GbTvWmB92F6SspKjSAjDOPJ_vY0cPwJTpW8lO61QiD0UhWoz6/s1600/large+aluminum+parts.JPG"><img style="WIDTH: 121px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566530678265854978" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiACEYRcDw5JhDtVw3YA0iwRVMe2fqMs6t2p8J9bg0-H1ZyjmbJqQw03OiAChD0Ty9Us8BultYt9blgOz_L32gSiJUakQ4GbTvWmB92F6SspKjSAjDOPJ_vY0cPwJTpW8lO61QiD0UhWoz6/s200/large+aluminum+parts.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzI87fAi-kYQ4tawMBW_XFA7FkiWyFRxweYqkJYpI-9WmVALBdd6zNHwFtktLmD2GlcCJKI8PU2lQ9hVq2vcK9fO741tCGEbm8vJP6upnYE6giqHDeg_Aj9aW8MrdhCVD5V7Plw7pqlRsV/s1600/large+aluminum+crucible.JPG"><img style="WIDTH: 132px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566530672694665090" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzI87fAi-kYQ4tawMBW_XFA7FkiWyFRxweYqkJYpI-9WmVALBdd6zNHwFtktLmD2GlcCJKI8PU2lQ9hVq2vcK9fO741tCGEbm8vJP6upnYE6giqHDeg_Aj9aW8MrdhCVD5V7Plw7pqlRsV/s200/large+aluminum+crucible.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAKjyEMJUvTo78x39K0pAPDbPmWpBTvSMKuJWU51doS55BHIFPkf8VgLzjcEkoZ2HgZIRa_deLGzbYztHNBpF9PiEeCHHllEOrs_2-88-pE2IASE46SvriSL-FxzUFwpV_7fFMAKtpqelw/s1600/aluminum+piston+melting.JPG"><img style="WIDTH: 126px; HEIGHT: 83px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566591816995469330" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAKjyEMJUvTo78x39K0pAPDbPmWpBTvSMKuJWU51doS55BHIFPkf8VgLzjcEkoZ2HgZIRa_deLGzbYztHNBpF9PiEeCHHllEOrs_2-88-pE2IASE46SvriSL-FxzUFwpV_7fFMAKtpqelw/s200/aluminum+piston+melting.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBDFYKGIWt7So72Pd3aw73Phrt_QKf7tjR72U-DQeg82UHhdkWKkeMvqAncRrUhc5Nym6Twit4uxsP7x3VaMaR5AH0lFL3bJXCkusLa0KNqwKHPgKNZ9ffOFrvFmSe0fiq0BKHX3YeuF1h/s1600/aluminum+scrap.JPG"><img style="WIDTH: 134px; HEIGHT: 83px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566604123296640338" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBDFYKGIWt7So72Pd3aw73Phrt_QKf7tjR72U-DQeg82UHhdkWKkeMvqAncRrUhc5Nym6Twit4uxsP7x3VaMaR5AH0lFL3bJXCkusLa0KNqwKHPgKNZ9ffOFrvFmSe0fiq0BKHX3YeuF1h/s200/aluminum+scrap.JPG" /></a><br /><u><strong><span style="color:#000066;">Another very important thing is always work with a dry ingot container and preheat the container before pouring the molten metal to prevent it from "poping" into your face and of course use full body protection gear while handling molten metal.</span></strong></u> I made a few large ingots using simple tin cans. It is very easy to cut them open in one vertical slice and after just to peal the sides off. Gloves are good to have to prevent cuts from the sharp edges.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8do6eK7-z19GBwIFHM-0X1PctggctR-swZ7gczxIfw6R6Tdw44yeRLNX6jceZrcTho4zu3hwYz6kEUk9fQUvXC1ez8_JXXr7tSDosdRL6mFTJU-0xfjXqpSwwrtVLGNKEez53MiEoc_PK/s1600/making+large+aluminum+ingots.JPG"><img style="WIDTH: 124px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566529696406738146" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8do6eK7-z19GBwIFHM-0X1PctggctR-swZ7gczxIfw6R6Tdw44yeRLNX6jceZrcTho4zu3hwYz6kEUk9fQUvXC1ez8_JXXr7tSDosdRL6mFTJU-0xfjXqpSwwrtVLGNKEez53MiEoc_PK/s200/making+large+aluminum+ingots.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_SHfQ64i9nELlpGZpwAJUZaiTDH0Ja48hsa9slYIr7qdXUbC7xURotNz9HM7V1TDbCfl1bo0H_-QJg6cusx0_93wMNPg99olHUo8JX_a4rdw4Lz35MA7gWPG21Qd-V6l62Z4XBQYnt0cY/s1600/aluminum+ingot.JPG"><img style="WIDTH: 141px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566530669537469858" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_SHfQ64i9nELlpGZpwAJUZaiTDH0Ja48hsa9slYIr7qdXUbC7xURotNz9HM7V1TDbCfl1bo0H_-QJg6cusx0_93wMNPg99olHUo8JX_a4rdw4Lz35MA7gWPG21Qd-V6l62Z4XBQYnt0cY/s200/aluminum+ingot.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5ogPw2hoLs7dPrK8laIzgjeTijQRNjQkhkrb_cwaWPWKjt1MhAY04ReBwr73DEPAnBKVj9Y-GdcnpVrIGU4LKD5G6GidTV-j3IXmx_zWhD-PP-OUF3dS8esebNOFtMl74LgfDRCTASm4B/s1600/www.flamingfurnace.blogspot.com.JPG"><img style="WIDTH: 117px; HEIGHT: 81px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566607313563138930" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5ogPw2hoLs7dPrK8laIzgjeTijQRNjQkhkrb_cwaWPWKjt1MhAY04ReBwr73DEPAnBKVj9Y-GdcnpVrIGU4LKD5G6GidTV-j3IXmx_zWhD-PP-OUF3dS8esebNOFtMl74LgfDRCTASm4B/s200/www.flamingfurnace.blogspot.com.JPG" /></a><br />Simple example for making a re-usable ingot tray is to weld a few L bars together or just using a tin muffin tray (Not aluminum). It all depends on what size of ingot is desired and how much molten metal is going to be poured into ingots.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcXLEdhHqGxhfMXlWuTanekKutklDYQtZ_POyGqmeSi4n5r4JGBi-SuV9lMfEZ9LNr6OGT3Y14k88lIIMM8Ach-62JKQosE3B9tdze1v-5TV11qG-N9LLqayZX-zmivrxihEOxGviGcjRF/s1600/long+aluminum+ingots..JPG"><img style="WIDTH: 127px; HEIGHT: 83px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566595754051869298" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcXLEdhHqGxhfMXlWuTanekKutklDYQtZ_POyGqmeSi4n5r4JGBi-SuV9lMfEZ9LNr6OGT3Y14k88lIIMM8Ach-62JKQosE3B9tdze1v-5TV11qG-N9LLqayZX-zmivrxihEOxGviGcjRF/s200/long+aluminum+ingots..JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzniarmVT4itUhpgShjB-2SuZHn04XMhlKzkIqZBsh5vcUfa41ifsUsMU11AGg6Jw_w4a-Zk6JVFB2sJLvrQeR6dpSip50WrJcC_EfhH0VWVZ7n4Y2S_LyeB_L0PzYIVm97Hn1CQRIGusX/s1600/large+aluminum+ingot.JPG"><img style="WIDTH: 106px; HEIGHT: 81px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566624029974887202" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzniarmVT4itUhpgShjB-2SuZHn04XMhlKzkIqZBsh5vcUfa41ifsUsMU11AGg6Jw_w4a-Zk6JVFB2sJLvrQeR6dpSip50WrJcC_EfhH0VWVZ7n4Y2S_LyeB_L0PzYIVm97Hn1CQRIGusX/s200/large+aluminum+ingot.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKTIZN21xNIyNx3FZxWALkj2zhRV0ftxMPzm07213Hx7zmrNzq07osAn5YyjIs1GhrYSI7a0fIcVb9QpsXP0FZaPijsduoYvV1WZRONxYwbARdSp5GhUg1Jwl_8K5_T-IJcRkEZYms84-o/s1600/molten+aluminum.JPG"><img style="WIDTH: 128px; HEIGHT: 83px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566626412646358274" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKTIZN21xNIyNx3FZxWALkj2zhRV0ftxMPzm07213Hx7zmrNzq07osAn5YyjIs1GhrYSI7a0fIcVb9QpsXP0FZaPijsduoYvV1WZRONxYwbARdSp5GhUg1Jwl_8K5_T-IJcRkEZYms84-o/s200/molten+aluminum.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbkrBxU3vd_ugCuQbOTAul6m9l3YMzLdsVksWlPbmQj7g4QchdZGIKYDEy36gSA4Ey-hpehaSRTemjHE7WYho5ixWmiQsFI5-TZ8diiuWdXGmAGLWQptsnfHqTAC9fXUQumsHTgv0gQOS7/s1600/aluminum+objects+into+aluminum+ingots..JPG"><img style="WIDTH: 115px; HEIGHT: 83px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566595754328332418" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbkrBxU3vd_ugCuQbOTAul6m9l3YMzLdsVksWlPbmQj7g4QchdZGIKYDEy36gSA4Ey-hpehaSRTemjHE7WYho5ixWmiQsFI5-TZ8diiuWdXGmAGLWQptsnfHqTAC9fXUQumsHTgv0gQOS7/s200/aluminum+objects+into+aluminum+ingots..JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg73G9a5CppXvuwEWSihrSgvqc1iGLeqCrfc1-fxQgzlTJ-2C_kMLQ6TSrTy4NlLLrhRjy-0O3XrZ7LRzMEcp-yZcaESvmBfiDiX9IUW5H4qZpYGxnmWp78geQzq8TzoSYQb8wdsvCkW3G0/s1600/aluminum+brackets+into+ingots.JPG"><img style="WIDTH: 136px; HEIGHT: 84px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566597688268208066" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg73G9a5CppXvuwEWSihrSgvqc1iGLeqCrfc1-fxQgzlTJ-2C_kMLQ6TSrTy4NlLLrhRjy-0O3XrZ7LRzMEcp-yZcaESvmBfiDiX9IUW5H4qZpYGxnmWp78geQzq8TzoSYQb8wdsvCkW3G0/s200/aluminum+brackets+into+ingots.JPG" /></a><br />Before you know it you will have a pile of aluminum ingots ready for some quality sand casting............ Good luck... and work safe ;-)<br />First clip pouring round aluminum ingots:<br /><object width="250" height="212"><param name="movie" value="http://www.youtube-nocookie.com/v/8rERmIN4O_o?fs=1&hl=en_US&rel=0"><param name="allowFullScreen" value="true"><param name="allowscriptaccess" value="always"><br /><embed src="http://www.youtube-nocookie.com/v/8rERmIN4O_o?fs=1&hl=en_US&rel=0" type="application/x-shockwave-flash" allowscriptaccess="always" allowfullscreen="true" width="250" height="212"></embed></object><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjceslMNlE3bPAnlNBIOt85HIly7zq_tBuhyeTLLys33U6DyOWSynlpms83j2H0M2kYol_p9g-JEPJhRVLQ4OJm99SRwHtHgXUR5jJeDKtMrhM4vt7v3utN4GYeBgEV07h5ARO0vmqip0c/s1600/aluminum+ingot+bucket.JPG"><img style="WIDTH: 103px; HEIGHT: 91px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566597008103756770" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjceslMNlE3bPAnlNBIOt85HIly7zq_tBuhyeTLLys33U6DyOWSynlpms83j2H0M2kYol_p9g-JEPJhRVLQ4OJm99SRwHtHgXUR5jJeDKtMrhM4vt7v3utN4GYeBgEV07h5ARO0vmqip0c/s200/aluminum+ingot+bucket.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhd5OuYWmMI-UB-66CnTXKKMiq0m8UaCed3c7VDx4CM9irqVqjAU9eBC515Kr438iUGUp65IKYdUhYghv3yxrakxOkfXgcuOjV5zRE5tn7Ba38eoB3MobiX6rPnJzqnDjvKjRNobhpBKwnZ/s1600/aluminum+muffin+ingots.JPG"><img style="WIDTH: 117px; HEIGHT: 91px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5566610712671528002" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhd5OuYWmMI-UB-66CnTXKKMiq0m8UaCed3c7VDx4CM9irqVqjAU9eBC515Kr438iUGUp65IKYdUhYghv3yxrakxOkfXgcuOjV5zRE5tn7Ba38eoB3MobiX6rPnJzqnDjvKjRNobhpBKwnZ/s200/aluminum+muffin+ingots.JPG" /></a><---Aluminum ingots <div>Second clip pouring long and slim aluminum ingots:</div><div><iframe title="YouTube video player" height="217" src="http://www.youtube.com/embed/6WSnc2-FZgQ?rel=0" frameborder="0" width="250"></iframe><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgc-emGZgHOYrDpk-A_ebVV27ML1yY6tlXkBCFmrv35ah5C_ZJ_Eh1utMf5zPJpWpvmSvqCZlJxs9Dwo16gyFEwxV3FmIilpAoJPvc-YFDa2Uwqmv2yCT8XDRv61fkM7mMw12TKXqYn_E8r/s1600/slim+aluminum+ingots.JPG"><img style="WIDTH: 126px; HEIGHT: 200px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5570219703999931714" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgc-emGZgHOYrDpk-A_ebVV27ML1yY6tlXkBCFmrv35ah5C_ZJ_Eh1utMf5zPJpWpvmSvqCZlJxs9Dwo16gyFEwxV3FmIilpAoJPvc-YFDa2Uwqmv2yCT8XDRv61fkM7mMw12TKXqYn_E8r/s200/slim+aluminum+ingots.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4v7AmQ0wng0CUgIB564w2Icc0LaTEtOftkft8Wv0pYEYckH0C8FvE7_1NwxmoK7ayZbL4FckRgep8owTwc_BZoxWoiRe5HyhzqO8QZYjP803A3uK0IWRZd8dzTc9ITJv8b4EHTfaDH44F/s1600/aluminum_ingots.JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5570353190203976850" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4v7AmQ0wng0CUgIB564w2Icc0LaTEtOftkft8Wv0pYEYckH0C8FvE7_1NwxmoK7ayZbL4FckRgep8owTwc_BZoxWoiRe5HyhzqO8QZYjP803A3uK0IWRZd8dzTc9ITJv8b4EHTfaDH44F/s200/aluminum_ingots.JPG" /></a></div>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-30405137151256072812011-01-16T11:56:00.000-08:002013-01-04T12:03:52.015-08:00Casting New Aluminum bell coverThis is another quick project I made for my house. After painting the door last year the bell button looked a bit boring so I decided to make it look a bit more "attractive". The design is very basic and the pattern is made from MDF.<br />
MDF is not great for small patterns but it did the job, the hard part was getting the shape of the bell cover button cavity. So as I did with the <a href="http://flamingfurnace.blogspot.com/2010/12/sand-casting-aluminum-handle.html">aluminum handle </a>pattern (another project) I cut it into 4 parts, that makes it easier to get the mold out without breaking the sand. As for the button I shaped a small part of hard wood. After opening the flask I cut off the sprue and riser, I was lucky there was only a bit of shrinkage on the back of the bell cover because I was a bit short of molten aluminum. Some cleaning a bit of polish and It looks great.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3gjvn_ThyphenhyphenOhmHUxFwKgfKGeiAGrpBFwbz4zY-I0TlzDIYx0ywrZW_zPnisumUuVcCFxNy3Sr3AMEgL-Sh6CxvClfsgH8Z5HXsVBXEBus28gu8Qe9lLNfuyp-ogjyS6i3cudfm49LCHLt1/s1600/sand+casting+aluminum+bell+cover.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5562881662723509602" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3gjvn_ThyphenhyphenOhmHUxFwKgfKGeiAGrpBFwbz4zY-I0TlzDIYx0ywrZW_zPnisumUuVcCFxNy3Sr3AMEgL-Sh6CxvClfsgH8Z5HXsVBXEBus28gu8Qe9lLNfuyp-ogjyS6i3cudfm49LCHLt1/s200/sand+casting+aluminum+bell+cover.JPG" style="cursor: hand; height: 89px; width: 105px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg500uMU8F-mtpD2zURC9IFPxElWAuYrG2C1LeBHCeh28NRISYXl8TYrfhJqMIxZq6ROpJz9YOxbEjrgZHcBm0KBWhbm1Rl4U1ffd_TAxG-byZMoPZFnjs3WrxpyYxXgu66_5VCV5uTSALz/s1600/DSCF3142+%2528Custom%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5562881019556652594" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg500uMU8F-mtpD2zURC9IFPxElWAuYrG2C1LeBHCeh28NRISYXl8TYrfhJqMIxZq6ROpJz9YOxbEjrgZHcBm0KBWhbm1Rl4U1ffd_TAxG-byZMoPZFnjs3WrxpyYxXgu66_5VCV5uTSALz/s200/DSCF3142+%2528Custom%2529.JPG" style="cursor: hand; height: 80px; width: 107px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh90v0ENpfhdcZgAMfFbu0kU8COnWr0XLrZlbRdAxA03pknSf-JAm2V5IVd_9oF9yANHWyunKNZhyZXYb568eHSSUiElnJW5JOyu-twvW0VrzKjlYJ-Ai8kFoKB5jflXh3vncC0Dlm5KB_8/s1600/DSCN4804+%2528Custom%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5562886509523434098" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh90v0ENpfhdcZgAMfFbu0kU8COnWr0XLrZlbRdAxA03pknSf-JAm2V5IVd_9oF9yANHWyunKNZhyZXYb568eHSSUiElnJW5JOyu-twvW0VrzKjlYJ-Ai8kFoKB5jflXh3vncC0Dlm5KB_8/s200/DSCN4804+%2528Custom%2529.JPG" style="cursor: hand; height: 81px; width: 109px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7nDAnKBEjUIS1IA924nBNxf8H4dtR01X7brGXn3bK2PMw7_5qktZq01ksyGm4hpHgfc6C_jvprISmOHN0n_6SyCtKRq6N94MPbjxAAO6K7pii_J8Xuu2CIEUrCg92r9BbEt28WfYQz2zh/s1600/DSCN4794+%2528Custom%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5562881030100180962" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7nDAnKBEjUIS1IA924nBNxf8H4dtR01X7brGXn3bK2PMw7_5qktZq01ksyGm4hpHgfc6C_jvprISmOHN0n_6SyCtKRq6N94MPbjxAAO6K7pii_J8Xuu2CIEUrCg92r9BbEt28WfYQz2zh/s200/DSCN4794+%2528Custom%2529.JPG" style="cursor: hand; height: 81px; width: 108px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYfrgfN1nLZOVelT6WQDZtfdSMkn0r82qf6dlItzrrH6qyvVY1KJHApd04qKUfUp8OL3NSKI037HPrkOotttqeGzS_edCs6JJ5byfDllMbnq83GuIxWTy91-L_-n4SItJThno00pfcWysW/s1600/aluminum+bell+cover.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5562888847034891106" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYfrgfN1nLZOVelT6WQDZtfdSMkn0r82qf6dlItzrrH6qyvVY1KJHApd04qKUfUp8OL3NSKI037HPrkOotttqeGzS_edCs6JJ5byfDllMbnq83GuIxWTy91-L_-n4SItJThno00pfcWysW/s200/aluminum+bell+cover.JPG" style="cursor: hand; height: 80px; width: 106px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPs9f4izYEFK2Sz4kXEN5_eOyp8_LfhoeA7FgyY11_JCwsFQnDehgNp_RhqbfDicAFtNd_C1jkKBO6NK0y2dLIGB-iSHvk5fi60YZ1QwHeHLYBESo76qCBwwNV4WZJssSB_Db-eXEtwvMW/s1600/DSCN4482+%2528Custom%2529.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5562881022790703986" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPs9f4izYEFK2Sz4kXEN5_eOyp8_LfhoeA7FgyY11_JCwsFQnDehgNp_RhqbfDicAFtNd_C1jkKBO6NK0y2dLIGB-iSHvk5fi60YZ1QwHeHLYBESo76qCBwwNV4WZJssSB_Db-eXEtwvMW/s200/DSCN4482+%2528Custom%2529.JPG" style="cursor: hand; height: 82px; width: 109px;" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-13119539778139380812011-01-12T06:14:00.000-08:002011-08-16T15:03:28.391-07:00Sand casting Aluminum Key FobThis is a quick project I made casting aluminum Key fob. I made a small flask and a pattern from MDF. After a bit of metal filing and cleaning it looked really cool. The Key Fob could be carried in the pocket and even be used in case of emergency for self defence or for emergency car window exit ;-). I also combined a bit of paracord for this project the <a href="http://paracord-projects.blogspot.com/2010/03/snake-stich-handle-cover.html">Snake stitch guide</a> can be found in my <a href="http://paracord-projects.blogspot.com/">Paracord Projects blog</a>.
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HEIGHT: 81px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5561314238287641058" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7zaCiW4CG83MnydhsLCEu7q6NLtEptNl2bKcC_ed7yyLoGqMTbpD0BE7BXmy4OFD4iDVFrVRbwBD6wcQrSdQPeasOUVvfX4GGhfAGjoQxZ06sC91EK5w7kmENRmjmqYqjEPFM9ydR3YtN/s200/aluminum+key+fob3.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHgrL52dePZz_EZKk7o1DGg9IfYDauK1vkqYwtFRBvWS3UbF1qY46y89ddPaa0TRQ6vRKP1apZjE9lDwEe8ZiGu60BvQ-Reu9fP7C0-mTyJu4xojQVuJhA0ZGntZndmPl8yveLCoKWz0dQ/s1600/aluminum+key+fob5.JPG"><img style="WIDTH: 101px; HEIGHT: 80px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5561314522307239890" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHgrL52dePZz_EZKk7o1DGg9IfYDauK1vkqYwtFRBvWS3UbF1qY46y89ddPaa0TRQ6vRKP1apZjE9lDwEe8ZiGu60BvQ-Reu9fP7C0-mTyJu4xojQVuJhA0ZGntZndmPl8yveLCoKWz0dQ/s200/aluminum+key+fob5.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPB4nP_Tf0yFsVhl4efvmh3Z-GQTCVuwogjkbwb_NB8ri-TUfFJMyXpnwTdRh9eSrbtdmmA_mbnQcWXYJsK-fQ6y1X8m3n2ExHvl3Q1dkwvMAOlo64q_WB4SGUCsaHpCQ9EetIZcwYdW_A/s1600/aluminum+key+fob4.JPG"><img style="WIDTH: 102px; HEIGHT: 81px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5561314235520145954" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPB4nP_Tf0yFsVhl4efvmh3Z-GQTCVuwogjkbwb_NB8ri-TUfFJMyXpnwTdRh9eSrbtdmmA_mbnQcWXYJsK-fQ6y1X8m3n2ExHvl3Q1dkwvMAOlo64q_WB4SGUCsaHpCQ9EetIZcwYdW_A/s200/aluminum+key+fob4.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrlQ6LsDLYIhBn9wDQzFiq8z2xY2dfgxxkj6UCnVXcU38XoX7fafkKNuWlTyj8nNZZx6rqzDwtSP_SNhBzYu85jXbVRMphsV0sOFP96ebDIe_agBxUMteNms-hpKAFQ-gnrcLde0c9YuUk/s1600/aluminum+key+fob6.JPG"><img style="WIDTH: 106px; HEIGHT: 87px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5561314526254227170" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrlQ6LsDLYIhBn9wDQzFiq8z2xY2dfgxxkj6UCnVXcU38XoX7fafkKNuWlTyj8nNZZx6rqzDwtSP_SNhBzYu85jXbVRMphsV0sOFP96ebDIe_agBxUMteNms-hpKAFQ-gnrcLde0c9YuUk/s200/aluminum+key+fob6.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFTaZKDc_X2pDsdkZrB25HjDdx1k9DoMXacjJ94fz1etNDLR0wKCOzP2-ZbCVzbu9x0JAJWLwNq145E3sZOislPVP1VChcf-_zbDK5JhNnIkHsNY-LsNG5j2tIpm14DYadec0-c4lOOpaA/s1600/aluminum+key+fob7.JPG"><img style="WIDTH: 102px; HEIGHT: 86px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5561314528022912498" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFTaZKDc_X2pDsdkZrB25HjDdx1k9DoMXacjJ94fz1etNDLR0wKCOzP2-ZbCVzbu9x0JAJWLwNq145E3sZOislPVP1VChcf-_zbDK5JhNnIkHsNY-LsNG5j2tIpm14DYadec0-c4lOOpaA/s200/aluminum+key+fob7.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJaD6LpRgzP7cAFVQow04Jm77okSejxezAOWefjenlWavPw8P5WG0Nlo1owX8ZAViUulfQwdbAJAZUuSoQlzAVzmKI-ikxbZjMzVRjGHiIQvoNQPpm13jD8Tx6ORFgv-XTH0F9uUXvqAHV/s1600/aluminum+key+fob9.JPG"><img style="WIDTH: 102px; HEIGHT: 87px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5561314534904320434" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJaD6LpRgzP7cAFVQow04Jm77okSejxezAOWefjenlWavPw8P5WG0Nlo1owX8ZAViUulfQwdbAJAZUuSoQlzAVzmKI-ikxbZjMzVRjGHiIQvoNQPpm13jD8Tx6ORFgv-XTH0F9uUXvqAHV/s200/aluminum+key+fob9.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi51REzsUAj3t8kV2SBTsXg-1OmRSOoVtQT1OLuEM0uwmUbemniDyuh8kUzyJOCr7TEnvwi-s5IHd69r8EldOMRI7yNUAylsvhsRSRjQF96vy_JGAC096pQ_8TonCYNqrE9usQ0sS1ipkFp/s1600/aluminum+key+fob11.JPG"><img style="WIDTH: 115px; HEIGHT: 88px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5561314630676435138" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi51REzsUAj3t8kV2SBTsXg-1OmRSOoVtQT1OLuEM0uwmUbemniDyuh8kUzyJOCr7TEnvwi-s5IHd69r8EldOMRI7yNUAylsvhsRSRjQF96vy_JGAC096pQ_8TonCYNqrE9usQ0sS1ipkFp/s200/aluminum+key+fob11.JPG" /></a>
<br /><u>Some late addtion threaded adge to give it more interesting look.</u>
<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhw0gSHoVp-mmI7DWP9V2u7F7ZeA9IMyfwLpQ4QZ9ndPiCyxqRy_o4aSSPWFYfEJZuWJX4Gxe0HxXWQ5wq1q8g0xtr3D4Y3oM2CmHR8Pg9PrzckKCsyQ3KjWwqmUI_3CWofuMTAAigw7rk8/s1600/DSCF9356+%2528Small%2529.JPG"><img style="WIDTH: 150px; HEIGHT: 96px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5641577285646002626" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhw0gSHoVp-mmI7DWP9V2u7F7ZeA9IMyfwLpQ4QZ9ndPiCyxqRy_o4aSSPWFYfEJZuWJX4Gxe0HxXWQ5wq1q8g0xtr3D4Y3oM2CmHR8Pg9PrzckKCsyQ3KjWwqmUI_3CWofuMTAAigw7rk8/s200/DSCF9356+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPI19iQO_gIHLr32J6EePN0N5_gmPz2r60lcy4qQZho-AmHGjnxx-aGJ-8qL7M7nvhlgd6BGiW0PnFTbsFojyQm8u6dNWQajQO_eZEKIGNKo54pk2RIWyfp995qSWgBYajio7ItVJabCnz/s1600/DSCF9350+%2528Small%2529.JPG"><img style="WIDTH: 158px; HEIGHT: 93px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5641577280056616434" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPI19iQO_gIHLr32J6EePN0N5_gmPz2r60lcy4qQZho-AmHGjnxx-aGJ-8qL7M7nvhlgd6BGiW0PnFTbsFojyQm8u6dNWQajQO_eZEKIGNKo54pk2RIWyfp995qSWgBYajio7ItVJabCnz/s200/DSCF9350+%2528Small%2529.JPG" /></a>
<br />FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-32429165361863601712010-12-24T17:25:00.000-08:002011-05-07T14:54:37.071-07:00Sand casting aluminum handleLast week I was walking with my family near a frozen lake, we saw a small dog running into the middle of the lake while chasing ducks then falling straight into the ice cold water in the center of the frozen lake. The dogs owner made the crazy decision to try and walk on the frozen lake to save his dog. I was thinking it would be great if I had a long rope just for emergency for cases like this in my car. Anyway the dog was saved by his owner and I made a decision to place some rope in my car with a strong aluminum handle.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7odIfxXkElhETjdT_MYV2Nm69gXZRpCmJRfjPpWK9V4omadpwI48P-0VJREMWrY9D-0la20cZqIEYFBTmlv-4uNM33Pi9VdT2uO25tv2ScT83zFImFCuEoc95v30HRp9jkLO6UFQBU4uH/s1600/aluminum+handle+mdf+pattern.JPG"><img style="WIDTH: 107px; HEIGHT: 75px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554428856655557138" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7odIfxXkElhETjdT_MYV2Nm69gXZRpCmJRfjPpWK9V4omadpwI48P-0VJREMWrY9D-0la20cZqIEYFBTmlv-4uNM33Pi9VdT2uO25tv2ScT83zFImFCuEoc95v30HRp9jkLO6UFQBU4uH/s200/aluminum+handle+mdf+pattern.JPG" /></a> I started by making pattern for my sand casting using 20mm MDF. First I drew the shape of the handle making a few corrections along the way. After the drawing was done I used my drill with a core bit and jig saw to cut the handle shape. I used a wood chisel to shape and round the grabbing part for the fingers. Last I gave it a good sanding and used acrylic paint over it.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIdEwLPTWI3MG0T1KDkDoTQ91j57G5KySV1B3SoSaf6Arm1e3ZW0dsokFkNlL1Cb0nwUbcG8NXZvjkOsEKknXuetcVWJyoWcx529OJOn4as2fDkYauKCWUW058sDjX8dwbP_ATCZSJ0GaQ/s1600/aluminum+handle+sand+casting+stages.JPG"><img style="WIDTH: 98px; HEIGHT: 76px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554989699135868626" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIdEwLPTWI3MG0T1KDkDoTQ91j57G5KySV1B3SoSaf6Arm1e3ZW0dsokFkNlL1Cb0nwUbcG8NXZvjkOsEKknXuetcVWJyoWcx529OJOn4as2fDkYauKCWUW058sDjX8dwbP_ATCZSJ0GaQ/s200/aluminum+handle+sand+casting+stages.JPG" /></a> After I opened the flask and the mould was ready I removed the pattern and cut it into 4 parts clamping it back to create the inner handle core parts. The reason I cut it is to get good quality sand casting. It is impossible to press the sand out of the pattern without breaking it if the pattern is in one part.<br />I released the clamps and carefully took the pattern out. Now I have the two inner core parts. I placed them in the correct place in the flask and after close the flask tight with large clamps.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgQEej0xKwqb5nH6uvhP5Sc8v1mYBq7lq9eG16gO7UShKv59KMUjdvPBwRFuEiN7sg-9SLrrmWSCnOaPuGEvyXSHSkIvzxpL8NaYdYGkilKAS4VDbvqIssIDrDvND8dEf07oeidcAh0CfX/s1600/sand+casting+parting+powder.JPG"><img style="WIDTH: 96px; HEIGHT: 68px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554429560034212914" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgQEej0xKwqb5nH6uvhP5Sc8v1mYBq7lq9eG16gO7UShKv59KMUjdvPBwRFuEiN7sg-9SLrrmWSCnOaPuGEvyXSHSkIvzxpL8NaYdYGkilKAS4VDbvqIssIDrDvND8dEf07oeidcAh0CfX/s200/sand+casting+parting+powder.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPvqDNMCP68NF1h-Y5p1blLje4IWxvFCHuZK3Cew7chrhd-V9inPtC6mLhogHryDOIlM8hZUP02TS9U8BMkD5I-PJhHnt3EWVfLrUZ5QxmgPGvU0QGC9GYyA_I_LkIcltUuwO_CjwEcGz-/s1600/sand+casting+mould.JPG"><img style="WIDTH: 88px; HEIGHT: 68px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554429574336791602" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPvqDNMCP68NF1h-Y5p1blLje4IWxvFCHuZK3Cew7chrhd-V9inPtC6mLhogHryDOIlM8hZUP02TS9U8BMkD5I-PJhHnt3EWVfLrUZ5QxmgPGvU0QGC9GYyA_I_LkIcltUuwO_CjwEcGz-/s200/sand+casting+mould.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgo1A48-JaHRCV5s4njqPD2bzDqmL8e0t1nXBZe8Qz5tpc20JLm5ZkLbdApriL8XOyuRFaZQv9FEnWQ6T8MTYNWTZHUax3snJeU0DUdU6NapR0HbyLNM5G2sMjeH3q-lw8VZUkeKIbEDiA8/s1600/cut+mdf+pattern.JPG"><img style="WIDTH: 97px; HEIGHT: 69px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554429574165157666" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgo1A48-JaHRCV5s4njqPD2bzDqmL8e0t1nXBZe8Qz5tpc20JLm5ZkLbdApriL8XOyuRFaZQv9FEnWQ6T8MTYNWTZHUax3snJeU0DUdU6NapR0HbyLNM5G2sMjeH3q-lw8VZUkeKIbEDiA8/s200/cut+mdf+pattern.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjj0a5RXQitfl6Q4XbLGMZdJ91r_RRVYgEEWbNYJ_ulu1Sqsx_sycQNe-CBYWfUAYoEgOsxC_qSSlCL0Qd6MuOcu0FZ7I2IH2t7j-sAT7x6eGRvdaFdZFUWrclmk1AzztODXcExNTHZZ83v/s1600/clamp+pattern.JPG"><img style="WIDTH: 99px; HEIGHT: 68px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554429576452339522" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjj0a5RXQitfl6Q4XbLGMZdJ91r_RRVYgEEWbNYJ_ulu1Sqsx_sycQNe-CBYWfUAYoEgOsxC_qSSlCL0Qd6MuOcu0FZ7I2IH2t7j-sAT7x6eGRvdaFdZFUWrclmk1AzztODXcExNTHZZ83v/s200/clamp+pattern.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf5hIsnxdocMCSngt2Yetwwd1zjAHJvtiFgmWnYruUmhqImj2l7YcBhtKKu5ofs-Yn3yMOv0NQ6gwmz0FAp-qZEtaiiU01gk2FbDexGm9oCKlRQMCCYtj-UEPOT_oOVIVol6AbwMKHvAvI/s1600/cutting+mdf+pattern.JPG"><img style="WIDTH: 106px; HEIGHT: 68px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554429576019723602" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf5hIsnxdocMCSngt2Yetwwd1zjAHJvtiFgmWnYruUmhqImj2l7YcBhtKKu5ofs-Yn3yMOv0NQ6gwmz0FAp-qZEtaiiU01gk2FbDexGm9oCKlRQMCCYtj-UEPOT_oOVIVol6AbwMKHvAvI/s200/cutting+mdf+pattern.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0-q2nQuX-ihdlKEXidEHUY_-DizsJW9_BC9lj7KHU-WbMsGyk8KH0lT0M6I9CNIWgEhfYmPfQRfMJTruxE3fnAvbP_8xNM2f2dPJN4Hm2U0p1x33M-PHkAxN9IlJNKgjaZuzwHh8Z-jMm/s1600/DSCN4199+%2528Small%2529.JPG"><img style="WIDTH: 93px; HEIGHT: 68px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554432855819332978" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0-q2nQuX-ihdlKEXidEHUY_-DizsJW9_BC9lj7KHU-WbMsGyk8KH0lT0M6I9CNIWgEhfYmPfQRfMJTruxE3fnAvbP_8xNM2f2dPJN4Hm2U0p1x33M-PHkAxN9IlJNKgjaZuzwHh8Z-jMm/s200/DSCN4199+%2528Small%2529.JPG" /></a><br />In this casting I tried something new using two tin cans as a sprue and riser extensions. The cans are filled with petrobond and the cavity I made is bigger then the flasks sprue and riser. I was looked after pouring the molten metal and it worked very well. I could see the riser feeding the molten aluminum into the mould, really cool. See picture below of the riser extension.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCzG8IVVUUAs8N6kgNTE04K58VyuXRXYxC8QNKMGV7Zi6MCxMRwwa07kZRJVvQ_O9RstqW8icihHhFvGAvCeqDrAIZA4EaCvcySrjhUX4iV8PFrBqTDonb4xrH8wKKudimSN6nYD46Wn9G/s1600/sprue+and+rise.JPG"><img style="WIDTH: 107px; HEIGHT: 87px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554433633602129874" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCzG8IVVUUAs8N6kgNTE04K58VyuXRXYxC8QNKMGV7Zi6MCxMRwwa07kZRJVvQ_O9RstqW8icihHhFvGAvCeqDrAIZA4EaCvcySrjhUX4iV8PFrBqTDonb4xrH8wKKudimSN6nYD46Wn9G/s200/sprue+and+rise.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhoDukibi4kenAJWhxoNFp0MuMbswhaZ2yA5ay1446ZTCb0aB_GTIh2eXIHmo66U1157ajlMVACmaXI7z1HFthvZD0M2EBhhi5DoXbYZy0dll6NM80VlbVhY8uQpWRGERSpb7NoP1itFk-/s1600/flask+open.JPG"><img style="WIDTH: 112px; HEIGHT: 83px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554433880752673026" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhoDukibi4kenAJWhxoNFp0MuMbswhaZ2yA5ay1446ZTCb0aB_GTIh2eXIHmo66U1157ajlMVACmaXI7z1HFthvZD0M2EBhhi5DoXbYZy0dll6NM80VlbVhY8uQpWRGERSpb7NoP1itFk-/s200/flask+open.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYttYChxMrnmXNLJ6Z8cD8wMTh2gauLI_x20VE4pHqrUNrZu1P1GURzeV7YSv33Pdm14-70e5sgdG9z-6qa23hzJ4gnqUjWJmbQ4r8Bl-bPM9ywuauzt67-L9Z0Erfb5ZzJ1uKAsxrS2de/s1600/new+aluminum+handle.JPG"><img style="WIDTH: 110px; HEIGHT: 88px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554433640917727250" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYttYChxMrnmXNLJ6Z8cD8wMTh2gauLI_x20VE4pHqrUNrZu1P1GURzeV7YSv33Pdm14-70e5sgdG9z-6qa23hzJ4gnqUjWJmbQ4r8Bl-bPM9ywuauzt67-L9Z0Erfb5ZzJ1uKAsxrS2de/s200/new+aluminum+handle.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhfQX3_XjilnZYlq0Qfcc0TR9x3g2CtiHPK6hggNhyphenhyphenQRJoJrLz7AQ_41JR3fjQdf-gVSZgMK2Qc9leUY-k-N4DCA1xe99-H9DF5fLD1tcU1K_OH_LTV4QiQZfqF_HWqaBdVZoGp-_HdapS/s1600/riser+feeding+aluminum.JPG"><img style="WIDTH: 128px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554433645383772802" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhfQX3_XjilnZYlq0Qfcc0TR9x3g2CtiHPK6hggNhyphenhyphenQRJoJrLz7AQ_41JR3fjQdf-gVSZgMK2Qc9leUY-k-N4DCA1xe99-H9DF5fLD1tcU1K_OH_LTV4QiQZfqF_HWqaBdVZoGp-_HdapS/s200/riser+feeding+aluminum.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTLL1TZcQF1xcPH3UBPfO9hZtz-WKBNmYSPurwHhCOmj4qZ17021eueMaqOpwXE2n3hyphenhyphenZeK55ixzRRJJdhgAd7KYqzYz7amiafamjtHzfPalEUIkyYhy6sWTyYWmaT0I7nfYrEuS8usI3O/s1600/riser+sprue+are+cut+off.JPG"><img style="WIDTH: 121px; HEIGHT: 86px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554433884144629074" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTLL1TZcQF1xcPH3UBPfO9hZtz-WKBNmYSPurwHhCOmj4qZ17021eueMaqOpwXE2n3hyphenhyphenZeK55ixzRRJJdhgAd7KYqzYz7amiafamjtHzfPalEUIkyYhy6sWTyYWmaT0I7nfYrEuS8usI3O/s200/riser+sprue+are+cut+off.JPG" /></a><br />I cut the sprue and riser with my hack saw and used a metal file to chip off the extra aluminum, then I drilled a hole for the rope and used an electric sander with different sand paper grades. After the sanding part I used fine metal wool for the final polish. To get an even better polish results it could be done with aluminum polishing products and a buffing wheel.<br />The rope fits very well into the handle hole and the handle is very comfortable for grabbing. The handle is heavy enough to be used as a weight in case it has to be thrown.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaCvf3KN8LYqi3OZDc9-hTxrYX1pQkImWD1EPEsthzJTpRvnQCPp1ahtgsZgKlF4aPRS7UvLNq1NsGKgp118DN90Bs8bg_XR3njF0S89c8Ps83Pp2hCTydbE50i_sg_nQWIX4TCASVahxZ/s1600/hole+for+rope.JPG"><img style="WIDTH: 123px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554436639713809378" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaCvf3KN8LYqi3OZDc9-hTxrYX1pQkImWD1EPEsthzJTpRvnQCPp1ahtgsZgKlF4aPRS7UvLNq1NsGKgp118DN90Bs8bg_XR3njF0S89c8Ps83Pp2hCTydbE50i_sg_nQWIX4TCASVahxZ/s200/hole+for+rope.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgal4oMo0uU_3a_auw8xbU72HtUIIhJEuLlKsW-3ynNyllaMwGSMJN01kk7aD1-ZPC-NsXVKqAikiCJyT4GkwxxYFw8hXsuYuco-aDsj0syccaTDRR9zNSuVtuWT9AWjA1T04UJ2n5lZkgA/s1600/polished+aluminum+handle.JPG"><img style="WIDTH: 107px; HEIGHT: 81px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554436924986275330" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgal4oMo0uU_3a_auw8xbU72HtUIIhJEuLlKsW-3ynNyllaMwGSMJN01kk7aD1-ZPC-NsXVKqAikiCJyT4GkwxxYFw8hXsuYuco-aDsj0syccaTDRR9zNSuVtuWT9AWjA1T04UJ2n5lZkgA/s200/polished+aluminum+handle.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizTTT_vWpf9aPMMm6k7B6VkO_-Qig2B3aGFbpEiXhIqClrnpqNGNpKt_aW0ieqAiIdCze4U50gTnlHhCWe2-hq-nqFvxFCO9ZPG4KgQZ0oiwP6_BrWNY2cQgR01NU-G4qc_7Xy4-ecYKya/s1600/DSCN4341+%2528Small%2529.JPG"><img style="WIDTH: 114px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554436631841983586" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizTTT_vWpf9aPMMm6k7B6VkO_-Qig2B3aGFbpEiXhIqClrnpqNGNpKt_aW0ieqAiIdCze4U50gTnlHhCWe2-hq-nqFvxFCO9ZPG4KgQZ0oiwP6_BrWNY2cQgR01NU-G4qc_7Xy4-ecYKya/s200/DSCN4341+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4YDgTHW3CB3MF7rSLhOqrgbqOmZ7ua2A40tv-YA_7tAXru8rTzHK4xFbh3TFRSvesX1yJHIQ0lnHfPl_jcwjbAWJteHBiasPrerGCd9Q44SWtbQklB7RXY5VTAGbNjRJO_CngfO-1KTLs/s1600/DSCN4350+%2528Small%2529.jpg"><img style="WIDTH: 135px; HEIGHT: 84px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5554436635905976914" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4YDgTHW3CB3MF7rSLhOqrgbqOmZ7ua2A40tv-YA_7tAXru8rTzHK4xFbh3TFRSvesX1yJHIQ0lnHfPl_jcwjbAWJteHBiasPrerGCd9Q44SWtbQklB7RXY5VTAGbNjRJO_CngfO-1KTLs/s200/DSCN4350+%2528Small%2529.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoVrvkL-w7Si68TUePfFGIzpaZlyv2ZodSu4kvbGZsEEf1LIYmn0HGsnnsYwAtygP23pIE5x0epxNxkLNrrb8KYEuDns3-71K8ylD2qJopztbrGRTTh1FcbqSivfIZ_FSKdM6PHjrz1VIp/s1600/polished+aluminum+handle.JPG"><img style="WIDTH: 146px; HEIGHT: 96px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5604095756236375234" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoVrvkL-w7Si68TUePfFGIzpaZlyv2ZodSu4kvbGZsEEf1LIYmn0HGsnnsYwAtygP23pIE5x0epxNxkLNrrb8KYEuDns3-71K8ylD2qJopztbrGRTTh1FcbqSivfIZ_FSKdM6PHjrz1VIp/s200/polished+aluminum+handle.JPG" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-78220921370528786772010-12-18T10:51:00.000-08:002011-03-10T01:48:08.470-08:00Foundry gas burnerAfter using charcoals for some time I started powering my furnace with propane gas. I started by constructing 2 burners and after a few uses I have to say its great regarding cleanliness and aluminum melting results. In this image I melted a bar of aluminum in just a few minutes and finished with many more ingots.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTf-pc6GOWhByVxmrwKuyWGxakXoywwVDo38meONZDmghlr6M2jBSHndgOvU20C_jXH5eWRpTRrnHCT7quffP9j6AT2LKVT0TqXu36ovulNJnJbGHwYBu5vlkE9QZ-Qku0Td9LpggSWvgY/s1600/melting_aluminum_with_propane_burner.JPG"><img style="WIDTH: 88px; HEIGHT: 76px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5552159415741490946" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTf-pc6GOWhByVxmrwKuyWGxakXoywwVDo38meONZDmghlr6M2jBSHndgOvU20C_jXH5eWRpTRrnHCT7quffP9j6AT2LKVT0TqXu36ovulNJnJbGHwYBu5vlkE9QZ-Qku0Td9LpggSWvgY/s200/melting_aluminum_with_propane_burner.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKA6ZBoAYv6BRvgQCYXNP2jf8sTArnc88xs-xaXl-1KcoAvIi5nS-X81ewyUXN1m3J34cUMwCK9JYwKcG8WK7v3XN709qRDtvzwY8p7GhrZzc2ltjtd_gzn0OMPKZ_1wc2_wt4Q2mHqBqS/s1600/propane_melting_aluminum.JPG"><img style="WIDTH: 96px; HEIGHT: 74px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5552162519495346722" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKA6ZBoAYv6BRvgQCYXNP2jf8sTArnc88xs-xaXl-1KcoAvIi5nS-X81ewyUXN1m3J34cUMwCK9JYwKcG8WK7v3XN709qRDtvzwY8p7GhrZzc2ltjtd_gzn0OMPKZ_1wc2_wt4Q2mHqBqS/s200/propane_melting_aluminum.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDMIy29lJxSVX3TNK0ef9fu-wudhS4ePCAkWvZXNvp8EuCETPJqd7JWF3tTEToKaBeohGnQnUSC2CqnnVGi_tX_IjUmEys3pSwlQGwfEYkv6BlYDZxPuLOHBOEJy68B5cbSsMWDMJd6K-O/s1600/slim+aluminum+ingots.JPG"><img style="WIDTH: 131px; HEIGHT: 75px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5575396524844352914" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDMIy29lJxSVX3TNK0ef9fu-wudhS4ePCAkWvZXNvp8EuCETPJqd7JWF3tTEToKaBeohGnQnUSC2CqnnVGi_tX_IjUmEys3pSwlQGwfEYkv6BlYDZxPuLOHBOEJy68B5cbSsMWDMJd6K-O/s200/slim+aluminum+ingots.JPG" /></a><br />The down side of using propane is that it's more expensive then charcoals or waste oil.<br />The first propane burner I made following <a href="http://prometheus.vndv.com/tutorial.html">Ben Baker's design</a> so many thanks to him for all his help and great sketchup design.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVVH6KGDKxVOJfbm-NK8oP2CLwDF8nmDx0WyX0i0VbReMWu4fGSOkz1r8LijdMeT53ETFeZvYGB-vKphysN2-T25k9kP-s6xkaQZqGiMFPBQiuwQzM0TSqxgxvinoEA8soPezjZazrTPWx/s1600/steel+square+stock.JPG"><img style="WIDTH: 87px; HEIGHT: 86px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5575397894057990498" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVVH6KGDKxVOJfbm-NK8oP2CLwDF8nmDx0WyX0i0VbReMWu4fGSOkz1r8LijdMeT53ETFeZvYGB-vKphysN2-T25k9kP-s6xkaQZqGiMFPBQiuwQzM0TSqxgxvinoEA8soPezjZazrTPWx/s200/steel+square+stock.JPG" /></a> The first burner is constructed from a stainless steel pipe nipple 1/2"x8", bell reducer 1/2"x3/4", mig welding tip 0.6-0.023, mig welding adaptor-m6-mb36, square steel stock 3/8"x3/8" and washer 3/4" (air choke plate).<br />The second burner is constructed from a stainless steel pipe nipple 3/4"x6", T-joint 3/4", copper head plug 3/4", mig welding tip 0.6-0.023, mig welding adaptor-m6-mb36 and a washer 3/4" (air choke).<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSgzZxeu6t-U5K2kmhrw80xEPrjLvKTwqNqDsd2v8GfCZuEOkXnhQXU8RPipFKsPN3ld6y4plPFBePNYzMelPIPYsFYItu_w5a5nFEz_gbY1CtnpSutUrSI4P7ifFuwK_UQSglyRoNmUWu/s1600/propane+burners.JPG"><img style="WIDTH: 120px; HEIGHT: 79px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5575398473105704722" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSgzZxeu6t-U5K2kmhrw80xEPrjLvKTwqNqDsd2v8GfCZuEOkXnhQXU8RPipFKsPN3ld6y4plPFBePNYzMelPIPYsFYItu_w5a5nFEz_gbY1CtnpSutUrSI4P7ifFuwK_UQSglyRoNmUWu/s200/propane+burners.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzPlK_XCfxH1jN2FSiGQ6gXZfMUpvSRf_t-lj04VMcdBjuQGhiX1zwuBxf7-4On1rCbPT2dla_H2LxT1K5XhdTyoyf2LUiEs4CbryA0JTo_V7KtqBiWhh83beb-Qq1SpNvPtF6xanWFFUC/s1600/propane_burners_parts.jpg"><img style="WIDTH: 127px; HEIGHT: 79px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5552155611654201346" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzPlK_XCfxH1jN2FSiGQ6gXZfMUpvSRf_t-lj04VMcdBjuQGhiX1zwuBxf7-4On1rCbPT2dla_H2LxT1K5XhdTyoyf2LUiEs4CbryA0JTo_V7KtqBiWhh83beb-Qq1SpNvPtF6xanWFFUC/s200/propane_burners_parts.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilgHBCod8eNb0pv5NhlCSQfHaPQlVFDQIPSuDRp8D_GQuFo0qnSfP6vqEMcOng9Iinj0n-9UkKaF8Vf8aDpWUMzAo8PIC306s2IIAzoswEsjR9i08_CDL02kgExei1ef9tArcwnwQ3wR5k/s1600/burner_chokes_adjusting.JPG"><img style="WIDTH: 129px; HEIGHT: 77px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5552156090209562082" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilgHBCod8eNb0pv5NhlCSQfHaPQlVFDQIPSuDRp8D_GQuFo0qnSfP6vqEMcOng9Iinj0n-9UkKaF8Vf8aDpWUMzAo8PIC306s2IIAzoswEsjR9i08_CDL02kgExei1ef9tArcwnwQ3wR5k/s200/burner_chokes_adjusting.JPG" /></a><br />To create the adjustable choke I drilled a hole in the (3/4") side of the bell reducer and top of the 3/4" T-joint. Making the threaded hole with a tap and die bit.<br />I used a 6mm bit to drill the copper plug fitting in the mig tip adaptor.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgenuJIKEw2vVPXgvXWnKXAtogpSEij6H0OU3K1PvZged752j8k-5SkQR0saF9oPcm8WhRtXN6pCSd-uQIlDHpzjFnZlBKZSKmv70Y8KTFZ8Ldm9dhIaC0x4TaVYeN5o9tQwy7lAJIGuORX/s1600/tip_adaptor_hole.JPG"><img style="WIDTH: 110px; HEIGHT: 78px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5552158729846520370" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgenuJIKEw2vVPXgvXWnKXAtogpSEij6H0OU3K1PvZged752j8k-5SkQR0saF9oPcm8WhRtXN6pCSd-uQIlDHpzjFnZlBKZSKmv70Y8KTFZ8Ldm9dhIaC0x4TaVYeN5o9tQwy7lAJIGuORX/s200/tip_adaptor_hole.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqprPGfnssawWJkES0Wl6OL0iFzgw0TClTamgWFkcAvjMKJ268yj0jfeKTTViIj25Xvs0Rr1b7w2ivlvWPGUvEkFX5dL_jkuS9lpOxbxx3FEQaP1xlROmLuklmSwtNReNfG7lTm2wOgkV3/s1600/choke_washer.JPG"><img style="WIDTH: 108px; HEIGHT: 77px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5552156986921573730" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqprPGfnssawWJkES0Wl6OL0iFzgw0TClTamgWFkcAvjMKJ268yj0jfeKTTViIj25Xvs0Rr1b7w2ivlvWPGUvEkFX5dL_jkuS9lpOxbxx3FEQaP1xlROmLuklmSwtNReNfG7lTm2wOgkV3/s200/choke_washer.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1lTeiWpragsryTX0pOtb6RLBB-LMtmsgdVCYOGM8Jc3bbO8-crMS6FqryyNolGn6TTerFB3ATK2X_X9tXv3WmWSB3cZp_hNePykR4pTntTjijZAzH-1wMfwy9rO5zqrSB4p5Nnqv-LzQ-/s1600/DSCN3880+%2528Small%2529.JPG"><img style="WIDTH: 114px; HEIGHT: 78px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5552156990692842658" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1lTeiWpragsryTX0pOtb6RLBB-LMtmsgdVCYOGM8Jc3bbO8-crMS6FqryyNolGn6TTerFB3ATK2X_X9tXv3WmWSB3cZp_hNePykR4pTntTjijZAzH-1wMfwy9rO5zqrSB4p5Nnqv-LzQ-/s200/DSCN3880+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrHyZpDs38BvSLthxgg8ooOwo4A80SyeruZ6LwV8svSZj2EkWMUiA4brQlPtPUUAsbujPyNrLWJKIgn99IZTJoOXsYWYTRcINcUGT7cfIfDxR5uqhPcg_W2RWGWkDjPd-n_hgUpAd5OyKU/s1600/chokesgif.gif"><img style="WIDTH: 112px; HEIGHT: 77px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5552156990311057922" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrHyZpDs38BvSLthxgg8ooOwo4A80SyeruZ6LwV8svSZj2EkWMUiA4brQlPtPUUAsbujPyNrLWJKIgn99IZTJoOXsYWYTRcINcUGT7cfIfDxR5uqhPcg_W2RWGWkDjPd-n_hgUpAd5OyKU/s200/chokesgif.gif" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSVy7WYt2e0eqxmWqx6UIT0SV1rm4dYQwuWv8IsLJokd2miGBEyoyRNOF_Xkqq1IYHhjBJ9bfN_IDSFZAtxgwarsKE0gpRHsVkBZJuodeK2oy9cgB94CYp9g9FFto96lTxGTC3ILY5hjhF/s1600/propane_choke_washer_open.JPG"><img style="WIDTH: 102px; HEIGHT: 77px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5552894254630388994" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSVy7WYt2e0eqxmWqx6UIT0SV1rm4dYQwuWv8IsLJokd2miGBEyoyRNOF_Xkqq1IYHhjBJ9bfN_IDSFZAtxgwarsKE0gpRHsVkBZJuodeK2oy9cgB94CYp9g9FFto96lTxGTC3ILY5hjhF/s200/propane_choke_washer_open.JPG" /></a><br />I tried to take some images of the propane burner in action changing the ratio mix of the air and gas but in the images the only flame that could be seen is oxidizing blue flame. Oxidizing blue flame can destroy metal pipe crucibles very quickly leaving a nice hole and a pool of molten aluminum in the bottom of the foundry.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRu9tfUAIcaSX_t_lUOO0_dd1g83hW1e0RjlIp1amNf6e8o0weAqjKGnWINjTDfUJXN_OFdLkh42iSwRWVdxYAhg0TTGj4TznY2T3S-N5XtUjNpesXZ_GTNFxwDSbgKfQBPlDaqQ7-sBv7/s1600/oxidising_flame.JPG"><img style="WIDTH: 114px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5552164174751887010" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRu9tfUAIcaSX_t_lUOO0_dd1g83hW1e0RjlIp1amNf6e8o0weAqjKGnWINjTDfUJXN_OFdLkh42iSwRWVdxYAhg0TTGj4TznY2T3S-N5XtUjNpesXZ_GTNFxwDSbgKfQBPlDaqQ7-sBv7/s200/oxidising_flame.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLtYldWWjwb4CFnT73ikHEm4zFR3gggy4uh1AGZxj5bvwKXFwQoBoFk_p5CQ9K6047PB7EpQjUdeu6_cxvz_TejpNSytwxZxnX8VcpcPEiyzMConwk4BtYUobAlySy_y2OQSM3Eq2fReS8/s1600/DSCN3896+%2528Small%2529.JPG"><img style="WIDTH: 117px; HEIGHT: 84px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5552164177627978354" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLtYldWWjwb4CFnT73ikHEm4zFR3gggy4uh1AGZxj5bvwKXFwQoBoFk_p5CQ9K6047PB7EpQjUdeu6_cxvz_TejpNSytwxZxnX8VcpcPEiyzMConwk4BtYUobAlySy_y2OQSM3Eq2fReS8/s200/DSCN3896+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1YDC2JKZAKBp2RB7FQI9EuJg66us97HnhqtgKyK9Lt5tn0WZdmyEvbvkpoUfQ-hsgoBLKaGHPpk6cIlkZb49gcgDqBuB45jsUq6A9VdgOqkf3_DxlO8ziRjPPoFJT33KyMESLSAGPCPzC/s1600/multimeter_test.JPG"><img style="WIDTH: 129px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5552164180769905106" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1YDC2JKZAKBp2RB7FQI9EuJg66us97HnhqtgKyK9Lt5tn0WZdmyEvbvkpoUfQ-hsgoBLKaGHPpk6cIlkZb49gcgDqBuB45jsUq6A9VdgOqkf3_DxlO8ziRjPPoFJT33KyMESLSAGPCPzC/s200/multimeter_test.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNjegnELKyqd81O9Fdwc-SYCkU79ElIhW0IESLneigG4ldy8Fa1tTuiukSft5kJMOTDcuirIhbL-SPUfXYy-saeEi0Cmrk2IPpu3TGcnc-DD3VBNXa9gyTcvBLOX0JXFT1aUWi9KBuInuc/s1600/propane_burner_in_use.JPG"><img style="WIDTH: 113px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5552164182556871394" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNjegnELKyqd81O9Fdwc-SYCkU79ElIhW0IESLneigG4ldy8Fa1tTuiukSft5kJMOTDcuirIhbL-SPUfXYy-saeEi0Cmrk2IPpu3TGcnc-DD3VBNXa9gyTcvBLOX0JXFT1aUWi9KBuInuc/s200/propane_burner_in_use.JPG" /></a><br />I haven't used an air blower combined with the propane burner before so I will try that in the future and post my experiment results. Once my foundry got to the right temperature I started pouring one crucible after the other for about 3 hours. The refractory insulation keeping all the heat inside the furnace is very important so it pays to make a good refractory.<br />Here is a video of my foundry in action using the propane burner before I installed the adjustable choke washer.................Next step a waste oil burner :-)<br /><object width="300" height="250"><param name="movie" value="http://www.youtube.com/v/aVsUVo9Ftt0?fs=1&hl=en_US&rel=0&color1=0xe1600f&color2=0xfebd01"><param name="allowFullScreen" value="true"><param name="allowscriptaccess" value="always"><br /><embed src="http://www.youtube.com/v/aVsUVo9Ftt0?fs=1&hl=en_US&rel=0&color1=0xe1600f&color2=0xfebd01" type="application/x-shockwave-flash" allowscriptaccess="always" allowfullscreen="true" width="300" height="250"></embed></object><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_Ei_E-SAnY_NzhIvk7zfThiYA7kE16F7g6ufINtG9cbvXSTf2O2Kz5s4sD4MEqFeHgHHYpBoxYTQloAyiI6W9vNn6A9A6vZDgStEVDqe0bFRzxN7sShYIpHFcdjGOeCUNVZCqKFjg74NJ/s1600/propane+burner.JPG"><img style="WIDTH: 186px; HEIGHT: 139px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5575399495986702450" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_Ei_E-SAnY_NzhIvk7zfThiYA7kE16F7g6ufINtG9cbvXSTf2O2Kz5s4sD4MEqFeHgHHYpBoxYTQloAyiI6W9vNn6A9A6vZDgStEVDqe0bFRzxN7sShYIpHFcdjGOeCUNVZCqKFjg74NJ/s200/propane+burner.JPG" /></a><br />This is another addition to my furnace, I used a screw to secure the burner into the correct location and angle.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXPFZroEwQQxkZbm3YPQH4IicQ7mKkzoELFNwtvu-aMIT8rs8yncM2is-LebsQKEsfpTdO5i_ahX7EBUo_HxipURpQ7Axefn1rsW49e2qlBjX_EW_qZaRshlvajzq1crXXEAzch5YSnwW2/s1600/burner+securing+screw.JPG"><img style="WIDTH: 150px; HEIGHT: 103px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5582385688323544962" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXPFZroEwQQxkZbm3YPQH4IicQ7mKkzoELFNwtvu-aMIT8rs8yncM2is-LebsQKEsfpTdO5i_ahX7EBUo_HxipURpQ7Axefn1rsW49e2qlBjX_EW_qZaRshlvajzq1crXXEAzch5YSnwW2/s200/burner+securing+screw.JPG" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-59904321367729868132010-12-10T13:14:00.001-08:002010-12-14T11:18:16.372-08:00Sand casting, aluminum Tap and Die handleA few days ago I was using my Tap and Die set, While making a simple threaded hole I used too much force on the handle and the aluminum part snapped broken. I decided to duplicate the part that broke using sand casting method. First I glued the two broken parts with super glue and after that it was easier to make the sand mould. It took me twice to make this tiny mould, to my opinion it's easier to create a mould of a bigger size object rather then working on a macro level making a small part. I also made a divider in a bigger flask to save time on ramming the petrobond. The casting result was very good just needed a bit of cleaning with metal file.<br />To create the holes and threaded holes on both sides I used my bench drill.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4LqvgCrk1eEax3wpSETiCcS2YUYViUjJZRZwNbyEHUObHFnbgdP0d0T6iyeeMDWN1YBqgBSQkzwU8JmYfKg8HwA-ni5UOD8pmYLKws0KjloephpCsC8SvSp2DoZeY8gPLQElA27tHksQO/s1600/DSCN4014+%2528Small%2529.jpg"><img style="WIDTH: 129px; HEIGHT: 91px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5549171396768312146" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4LqvgCrk1eEax3wpSETiCcS2YUYViUjJZRZwNbyEHUObHFnbgdP0d0T6iyeeMDWN1YBqgBSQkzwU8JmYfKg8HwA-ni5UOD8pmYLKws0KjloephpCsC8SvSp2DoZeY8gPLQElA27tHksQO/s200/DSCN4014+%2528Small%2529.jpg" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUxjrz5iXAQaz-obN3cOudBJBx1tjbUDlcOYBX1qsEjwCGt3s4jdXLWhy_rjdSbyTiqqiAWqoso3ww9oM05FIOsqcGqdEV7jAKkoJu4KMXPQcLD8BD23XCPBPcxdgE6STRr1UfEoQoYz79/s1600/DSCN4018+%2528Small%2529.JPG"><img style="WIDTH: 132px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5549171392792581474" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUxjrz5iXAQaz-obN3cOudBJBx1tjbUDlcOYBX1qsEjwCGt3s4jdXLWhy_rjdSbyTiqqiAWqoso3ww9oM05FIOsqcGqdEV7jAKkoJu4KMXPQcLD8BD23XCPBPcxdgE6STRr1UfEoQoYz79/s200/DSCN4018+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZNcVAaKxWKRTduOKeTBDSOZpEpsiIrP7-MmuPnfBldgWBIQw2ZBC8wwTWc3ypa82piGJrMiuuHPELcsA87seKwYgbXgQXwzNC-ZqyTr-w8bRV79DD6Dxahw94wqCQtVMnvI0ykEqO3E53/s1600/DSCN4019+%2528Small%2529.JPG"><img style="WIDTH: 135px; HEIGHT: 88px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5549171388742857730" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZNcVAaKxWKRTduOKeTBDSOZpEpsiIrP7-MmuPnfBldgWBIQw2ZBC8wwTWc3ypa82piGJrMiuuHPELcsA87seKwYgbXgQXwzNC-ZqyTr-w8bRV79DD6Dxahw94wqCQtVMnvI0ykEqO3E53/s200/DSCN4019+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7pJ0K18HKM3uOiYoq5TmSLVUKUi7kBA8plDVcNE6Skx1sjoc7vzmzUQxKyR6xWHNHf7araxh5u3lyoDqUYnPOcoAYQT_SrAw70h3s7fxLzYXVdxNYhB2jCMf3jvBYNEA-TU-l_p4_oerd/s1600/dscn4021+%2528Small%2529.JPG"><img style="WIDTH: 133px; HEIGHT: 87px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5549171236691004786" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7pJ0K18HKM3uOiYoq5TmSLVUKUi7kBA8plDVcNE6Skx1sjoc7vzmzUQxKyR6xWHNHf7araxh5u3lyoDqUYnPOcoAYQT_SrAw70h3s7fxLzYXVdxNYhB2jCMf3jvBYNEA-TU-l_p4_oerd/s200/dscn4021+%2528Small%2529.JPG" /></a><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-qPzEeBbfE2NxZAPCwca-vrBjMkZ5MLDCXLdm4gOdhlFwQEa_WKNiUP-S5wmV536LuG_hBP9aoGxr3qkHkofcS3t_4nZ_cfcERPlFnNHxTQfI20NusyPpya0oNOOL5ySR5wNlIn4l9_zx/s1600/DSCN4025+%2528Small%2529.JPG"><img style="WIDTH: 118px; HEIGHT: 89px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5549171225494936242" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-qPzEeBbfE2NxZAPCwca-vrBjMkZ5MLDCXLdm4gOdhlFwQEa_WKNiUP-S5wmV536LuG_hBP9aoGxr3qkHkofcS3t_4nZ_cfcERPlFnNHxTQfI20NusyPpya0oNOOL5ySR5wNlIn4l9_zx/s200/DSCN4025+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjl8YpP5AGLnGFZkV5ba1FiK0E9JYcWjegu_Kw5b2oDl8JFHe2iw9RDfAgNZSAkVQaH48Rkoy-7POQuSm0C_p_Wqd63d5OGmvTLjWRmzCtFTLO74cdYv2yVjTSmoTcZWBVRL2stfnFoIUeV/s1600/DSCN4048+%2528Small%2529.JPG"><img style="WIDTH: 113px; HEIGHT: 87px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5549171223665664114" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjl8YpP5AGLnGFZkV5ba1FiK0E9JYcWjegu_Kw5b2oDl8JFHe2iw9RDfAgNZSAkVQaH48Rkoy-7POQuSm0C_p_Wqd63d5OGmvTLjWRmzCtFTLO74cdYv2yVjTSmoTcZWBVRL2stfnFoIUeV/s200/DSCN4048+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHh7awa5Zb0hbyfTV0L9hLrDYgtWiqyVcinGZ0qm7UQvgJ88uFCVUzNFkYJbIeUYgdYQHbDod-oai5t2-ju5WCP7F2_5RZANPXCVENejF_ArU7vC3tAidU2RjPUAijd6IE7IB1Rb3nY_BQ/s1600/aluminum+casting.JPG"><img style="WIDTH: 114px; HEIGHT: 89px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5549176795027459570" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHh7awa5Zb0hbyfTV0L9hLrDYgtWiqyVcinGZ0qm7UQvgJ88uFCVUzNFkYJbIeUYgdYQHbDod-oai5t2-ju5WCP7F2_5RZANPXCVENejF_ArU7vC3tAidU2RjPUAijd6IE7IB1Rb3nY_BQ/s200/aluminum+casting.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8KXkqaPlUc0pcMV0YSoQNLfTnnepenzxNGi7Lyn_dPXQEZWZp_UGr7r1tBGpj8AE1xYMOaB1rVUug0yJYDMGCyxfm7dx-cGHqNDJIFApM5s5ZgNQASAINi_3LAQgLAvqQ7CANjwIykGv-/s1600/DSCN4054+%2528Small%2529.JPG"><img style="WIDTH: 127px; HEIGHT: 88px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5549171215670040882" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8KXkqaPlUc0pcMV0YSoQNLfTnnepenzxNGi7Lyn_dPXQEZWZp_UGr7r1tBGpj8AE1xYMOaB1rVUug0yJYDMGCyxfm7dx-cGHqNDJIFApM5s5ZgNQASAINi_3LAQgLAvqQ7CANjwIykGv-/s200/DSCN4054+%2528Small%2529.JPG" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-30037324325263088592010-11-25T13:08:00.000-08:002010-12-04T09:14:06.249-08:00Today I casted aluminum scoopI got some new scarp aluminum and my new propane burner was ready for his first test run. BTW I will post in the next few days how I built this propane burner.<br />I was amazed how quick the aluminum was melting in the crucible and it was a good opportunity to do some aluminum sand casting.<br />I looked around and I decided to duplicate my plastic scoop.<br />I used my large wooden flask it was just about the correct size. It takes about 10 minutes to make this easy mold. I used 2 rounded wooden toys to create the sprue and the riser, and my aluminum rammer I made to pack all the petrobond.<br />After my last few castings I realized that it is very handy to use one big clamp holding the drag, cope and base board tight together. The clamp also makes it easy to move flask around using the clamp as lifting handle. As for the pouring basin I used a tin can to avoid spilling molten metal over the wooden flask. I still have to give it a bit of cleaning and polish but the end result was very good. Now I have a new excellent aluminum scoop ;-)<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjdISXQXJ6ZDuijyJh-sj-UtY5aMwjislbnzN0pjIqa_yjJAJAgWQkg8a0Y0QDD4oiVoYsgR4xhMykTxihufl7unrRz-PeXZzT22k9HyIGEP_5MkAHH_Eg9tKLPMLW9CujwM2fTaTFx5N8/s1600/DSCN3711+%2528Small%2529.JPG"><img style="WIDTH: 88px; HEIGHT: 71px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5543603657474409842" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjdISXQXJ6ZDuijyJh-sj-UtY5aMwjislbnzN0pjIqa_yjJAJAgWQkg8a0Y0QDD4oiVoYsgR4xhMykTxihufl7unrRz-PeXZzT22k9HyIGEP_5MkAHH_Eg9tKLPMLW9CujwM2fTaTFx5N8/s200/DSCN3711+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5wos4r9oGSVAwsv9xIXB_dMjYQ9jVtjAygeQyHg_AJ8de1c6Bg-vX1zHAER2wD9FDKnBTL_XsSz1cGSdNmewESmJ__H2nOOzpcSu8YAigvrwcGnI-sI2TBLaHaQ8o-d7jljZ_NbmjPjX_/s1600/DSCN3712+%2528Small%2529.JPG"><img style="WIDTH: 89px; HEIGHT: 72px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5543603662115365026" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5wos4r9oGSVAwsv9xIXB_dMjYQ9jVtjAygeQyHg_AJ8de1c6Bg-vX1zHAER2wD9FDKnBTL_XsSz1cGSdNmewESmJ__H2nOOzpcSu8YAigvrwcGnI-sI2TBLaHaQ8o-d7jljZ_NbmjPjX_/s200/DSCN3712+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2s3gaCdDyzIOS0GjmBDzaaebdBfy-dvtkOWcielRkcjyL99I-rk8afBNUE4oWZK-iHPvXpSNJ31DFetrYbyavCP4r__i5-yL3Sl9bJ_v-5s_P8N_EAe9QJReAApNcK_oifjILGL8glcnb/s1600/DSCN3713+%2528Small%2529.JPG"><img style="WIDTH: 84px; 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HEIGHT: 71px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5543605580094279602" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxl2GyOQE234iAb5vLYIVdejGbtrs5uVxin8cIJ8CfIyxOLExNrffAUgTh6ZwoU261ynR5gBqjYMnO4cmg46L_qEOqju2ZJptO5abfGUQ1gaKKAbukmWzHtdSDcTes3HLSyPc7ae3biiuz/s200/DSCN3736+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRTWz3QiwzHv75E2UvdQhnUTMnRkF3__MVCumnYVfGwNSdEapWesWpJrtzOVgQYs5YF-eXG-n-5o3_rNdu7e5bOgLfSeQok1GNSdIv04SA9BTD7bFYu4xrJTA_rjFOIwkEyOE0zHTGH3VF/s1600/DSCN3746+%2528Small%2529.JPG"><img style="WIDTH: 95px; HEIGHT: 71px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5543605584894280146" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRTWz3QiwzHv75E2UvdQhnUTMnRkF3__MVCumnYVfGwNSdEapWesWpJrtzOVgQYs5YF-eXG-n-5o3_rNdu7e5bOgLfSeQok1GNSdIv04SA9BTD7bFYu4xrJTA_rjFOIwkEyOE0zHTGH3VF/s200/DSCN3746+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtZ59lLFuOhESXsslaep3wiL4z_Hc20eM9QaWqt0JumDIUHh7ZDeozJwad0wORqEeyexJ6BRoGlaGB36KGplU-AgQGWHtes4ba1pKWrYKauNjz7tXqSnBF3k83HDjs2CwN6VNxMnWcaBp8/s1600/DSCN3751+%2528Small%2529.JPG"><img style="WIDTH: 89px; HEIGHT: 73px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5543605852946303106" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtZ59lLFuOhESXsslaep3wiL4z_Hc20eM9QaWqt0JumDIUHh7ZDeozJwad0wORqEeyexJ6BRoGlaGB36KGplU-AgQGWHtes4ba1pKWrYKauNjz7tXqSnBF3k83HDjs2CwN6VNxMnWcaBp8/s200/DSCN3751+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8mPXjNCKnkeQJxuyprM5VQVqkJypLNgQqDgD4LJWLTNfBdtVrilq6C5XgAu3KPxa3tixU6MWJ0OXIJWidjO8-Zs4LryNTW9yJ8d6_IjSkGIIr5V7kzlz4nZWKeVFYKMLt53K5zKmI_h-a/s1600/DSCN3757+%2528Small%2529.JPG"><img style="WIDTH: 100px; HEIGHT: 75px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5543605875406486706" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8mPXjNCKnkeQJxuyprM5VQVqkJypLNgQqDgD4LJWLTNfBdtVrilq6C5XgAu3KPxa3tixU6MWJ0OXIJWidjO8-Zs4LryNTW9yJ8d6_IjSkGIIr5V7kzlz4nZWKeVFYKMLt53K5zKmI_h-a/s200/DSCN3757+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPzq0Hn4Rf5BiWsdUkLJNITHqtt6Qf3ljeLSWZIesgETHRLfaAzTqUC6NrwwLdubZFl1F41CWIeMXXXzWnoKd_ch2pC5zK64EOO3N-oGyhyphenhyphenJGyHWAwmLpHIrNUFo1jDhlHJsOsQlnupp-c/s1600/DSCN3753+%2528Small%2529.JPG"><img style="WIDTH: 131px; HEIGHT: 77px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5543605871706957362" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPzq0Hn4Rf5BiWsdUkLJNITHqtt6Qf3ljeLSWZIesgETHRLfaAzTqUC6NrwwLdubZFl1F41CWIeMXXXzWnoKd_ch2pC5zK64EOO3N-oGyhyphenhyphenJGyHWAwmLpHIrNUFo1jDhlHJsOsQlnupp-c/s200/DSCN3753+%2528Small%2529.JPG" /></a><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXW3jvkBZp3mumjjihED-8jl2loL4nD9BI2aIWjmgf3uHDgiF9U7vFf-bJneaAp65RZHbF9poBqwCpcXDiQalAn_IkZGh8aLKFj70U_FQsKGB8UPkw97ROzApzPFpXjJwtRsaGkOSR33fN/s1600/DSCN3952+%2528Small%2529.JPG"><img style="WIDTH: 168px; HEIGHT: 103px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5546876105753794514" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXW3jvkBZp3mumjjihED-8jl2loL4nD9BI2aIWjmgf3uHDgiF9U7vFf-bJneaAp65RZHbF9poBqwCpcXDiQalAn_IkZGh8aLKFj70U_FQsKGB8UPkw97ROzApzPFpXjJwtRsaGkOSR33fN/s200/DSCN3952+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpTFIquD9nk19r5zvFcYkcm_Ephg4BqzpajZmm9l0tMzQUwDqfe6PZf5igIEUtBYOwqHAANLShtdh7373kEZdxP03KQwg3OARkdymo8sqypQqsnm1d_mpOj5Hy1VmllMEV6eDA3r-uk9IR/s1600/DSCN3953+%2528Small%2529.JPG"><img style="WIDTH: 161px; HEIGHT: 103px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5546876106824839906" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpTFIquD9nk19r5zvFcYkcm_Ephg4BqzpajZmm9l0tMzQUwDqfe6PZf5igIEUtBYOwqHAANLShtdh7373kEZdxP03KQwg3OARkdymo8sqypQqsnm1d_mpOj5Hy1VmllMEV6eDA3r-uk9IR/s200/DSCN3953+%2528Small%2529.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJdeqAkcAWhyzUVda9moc4x6xwWnHeY8aW_ulW80Yj6NyqgSfPA4eMpjxWXsnzgFfnmz_jkBfQaNxlQZzC3W0XKZ7yi745gfliPp1runhAd3xXW7BPEbzjivSGW90tdJX5IkYAglvcB26f/s1600/DSCN3955+%2528Small%2529.JPG"><img style="WIDTH: 168px; HEIGHT: 103px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5546876118371824514" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJdeqAkcAWhyzUVda9moc4x6xwWnHeY8aW_ulW80Yj6NyqgSfPA4eMpjxWXsnzgFfnmz_jkBfQaNxlQZzC3W0XKZ7yi745gfliPp1runhAd3xXW7BPEbzjivSGW90tdJX5IkYAglvcB26f/s200/DSCN3955+%2528Small%2529.JPG" /></a> <br /><object width="300" height="220"><param name="movie" value="http://www.youtube.com/v/XrVqnDMU4m4?fs=1&hl=en_US&rel=0&color1=0x5d1719&color2=0xcd311b"><param name="allowFullScreen" value="true"><param name="allowscriptaccess" value="always"><embed src="http://www.youtube.com/v/XrVqnDMU4m4?fs=1&hl=en_US&rel=0&color1=0x5d1719&color2=0xcd311b" type="application/x-shockwave-flash" allowscriptaccess="always" allowfullscreen="true" width="300" height="220"></embed></object>Here is my video pouring the molten aluminumFlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-87489775416944870422010-11-08T08:48:00.000-08:002010-11-09T13:05:42.864-08:00Aluminum ship is finishedFinally all the parts are ready the next thing to do is grinding all the extra aluminum from the pouring. I used a grinder for cutting off the extra big chunks, metal chisel then sand paper (600 grit), after coarse metal wool and finally a fine metal wool. I could keep on polishing until it will look like a mirror but at the moment I am happy with the way it looks.<br />To attach all the parts I used a metal adhesive after all its just going to sit on the shelf. Another option is using aluminum welding or very small screws to attach all the parts.<br />I used the star trek insignia as a base for the ship drilling a 5mm hole for the metal rod.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj243Z1rOpbi61MpJdJopVmr2Y4D7YtCq1ZzhXWZM_wTJia6oZVBvZFKUcVzNrDN5tBUdrWFShnQnHErHn5RTiaEHgWSAJH5tOvxNW0D1OXkV-9zVIZh7FucOP1r2LD6HGKNGKbtJfFuhs5/s1600/DSCN3533+(Small).JPG"><img style="WIDTH: 108px; HEIGHT: 77px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5537222088800409346" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj243Z1rOpbi61MpJdJopVmr2Y4D7YtCq1ZzhXWZM_wTJia6oZVBvZFKUcVzNrDN5tBUdrWFShnQnHErHn5RTiaEHgWSAJH5tOvxNW0D1OXkV-9zVIZh7FucOP1r2LD6HGKNGKbtJfFuhs5/s200/DSCN3533+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJ_04X5MgSJT93FLh8yUslhYBMc79w2Ditrp9tHO8IEif8sHPYaI8bX7dsruhDcFdDv_OiXNILEPcWcLSv2_AHt4EDH75KMe4bwu9Xl6eqgX7db4ABY_24GZm3N1aT-kjseejdSnPuuHGE/s1600/DSCN3543+(Small).JPG"><img style="WIDTH: 108px; HEIGHT: 79px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5537222437098359234" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJ_04X5MgSJT93FLh8yUslhYBMc79w2Ditrp9tHO8IEif8sHPYaI8bX7dsruhDcFdDv_OiXNILEPcWcLSv2_AHt4EDH75KMe4bwu9Xl6eqgX7db4ABY_24GZm3N1aT-kjseejdSnPuuHGE/s200/DSCN3543+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0LmXJe-mYqkuHolJxkSmq7EkeXe13zLkP0ZahUvB-QbWZjsA9S7udlg_9ooD-qgaxmPCmfFjo36FNRERLy4hyphenhyphen-Wd83FrcBvFqx29iIQ_aGQsMxmcTtUdq1ChtRD8tlflmzCU7yu66Xrn5/s1600/DSCN3494+(Small).JPG"><img style="WIDTH: 102px; HEIGHT: 78px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5537222064782953426" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0LmXJe-mYqkuHolJxkSmq7EkeXe13zLkP0ZahUvB-QbWZjsA9S7udlg_9ooD-qgaxmPCmfFjo36FNRERLy4hyphenhyphen-Wd83FrcBvFqx29iIQ_aGQsMxmcTtUdq1ChtRD8tlflmzCU7yu66Xrn5/s200/DSCN3494+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWh6ezTj8CDhbJyldW_AFCI6MoUjlRZfXBP4hRaK5WfjduW3JOjkmsQcBmObYS4qV5Ywy17-DLVNlANXbpHbCHAkbIrn6pKAju0INCCvGhoH2Z0Y6iY1C8hJkcsk7qg_cOQ7m89FFhCy5p/s1600/DSCN3506+(Small).JPG"><img style="WIDTH: 109px; HEIGHT: 77px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5537222073983356578" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWh6ezTj8CDhbJyldW_AFCI6MoUjlRZfXBP4hRaK5WfjduW3JOjkmsQcBmObYS4qV5Ywy17-DLVNlANXbpHbCHAkbIrn6pKAju0INCCvGhoH2Z0Y6iY1C8hJkcsk7qg_cOQ7m89FFhCy5p/s200/DSCN3506+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgh8NahMthcuFn08ToL4MCvCye6ILJiLD2QhwH-9JUo63wzGGmxKPdQv9LNEVUB7kQ4GQ48cpLEu0yFcdCixCxD3aljL0C9pwepVbKRaFUVo0APA4MoH5Qgk9-w9vcANHirITbs7EUaADW1/s1600/DSCN3530+(Small).JPG"><img style="WIDTH: 119px; HEIGHT: 78px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5537222081086497314" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgh8NahMthcuFn08ToL4MCvCye6ILJiLD2QhwH-9JUo63wzGGmxKPdQv9LNEVUB7kQ4GQ48cpLEu0yFcdCixCxD3aljL0C9pwepVbKRaFUVo0APA4MoH5Qgk9-w9vcANHirITbs7EUaADW1/s200/DSCN3530+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCtWJgJwdV2ahRsj-2UogyKHWKJmYzc4SLtYHJII-BsentCYZCUrfJHfvxOhJkeY35B7eoCbEpPMADDFE5kSi9NEgnNTpPl01rd_s73QINjsM_hOgEZpD_uhr-MUPQ54gngaDOxBFx2Rda/s1600/DSCN3536+(Small).JPG"><img style="WIDTH: 90px; HEIGHT: 80px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5537222091019498786" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCtWJgJwdV2ahRsj-2UogyKHWKJmYzc4SLtYHJII-BsentCYZCUrfJHfvxOhJkeY35B7eoCbEpPMADDFE5kSi9NEgnNTpPl01rd_s73QINjsM_hOgEZpD_uhr-MUPQ54gngaDOxBFx2Rda/s200/DSCN3536+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOr91EWlQYhmka_dRw5N4WtJk3YLlU4lKthIsm2n2cP5cSweDKV2DgLFYwKK53XBJ29IhPBako4WzZfUXWQZM-QLdn83Q94CZSCzTZnOqiQ1Kfnh4_qREmF5bZwzE6yzOD76JcQJHYBVcc/s1600/DSCN3545+(Small).JPG"><img style="WIDTH: 129px; HEIGHT: 108px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5537222445369608354" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOr91EWlQYhmka_dRw5N4WtJk3YLlU4lKthIsm2n2cP5cSweDKV2DgLFYwKK53XBJ29IhPBako4WzZfUXWQZM-QLdn83Q94CZSCzTZnOqiQ1Kfnh4_qREmF5bZwzE6yzOD76JcQJHYBVcc/s200/DSCN3545+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjklqTcKwqCsLmbTMc_-7Wyq4orWKKsjPdf-UFnunOyXYDpHtO3dudUoIje8UDpGnficeMIh2brXSTDyTCvEwsHayS4gC7OPiqfTDCsmU5oi64wQk__QnKHcL22yoVUwT3AN3RW_PThLkyh/s1600/DSCN3547+(Small).JPG"><img style="WIDTH: 131px; HEIGHT: 107px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5537223063910664050" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjklqTcKwqCsLmbTMc_-7Wyq4orWKKsjPdf-UFnunOyXYDpHtO3dudUoIje8UDpGnficeMIh2brXSTDyTCvEwsHayS4gC7OPiqfTDCsmU5oi64wQk__QnKHcL22yoVUwT3AN3RW_PThLkyh/s200/DSCN3547+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGhJ4fdyQYgMfUcAUZFQn8JGRS8PKuuhGe42lw_HB_bTtpHtdXUyzYgY48K7hBkAXxM5xyrG3hatMxyvX6Xi3TeINjMJP55zBVUzQC7iFoY314OonWGx64TIubWF5LHqFC1_w6axeUyLP-/s1600/DSCN3546+(Small).JPG"><img style="WIDTH: 144px; HEIGHT: 109px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5537222456520983442" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGhJ4fdyQYgMfUcAUZFQn8JGRS8PKuuhGe42lw_HB_bTtpHtdXUyzYgY48K7hBkAXxM5xyrG3hatMxyvX6Xi3TeINjMJP55zBVUzQC7iFoY314OonWGx64TIubWF5LHqFC1_w6axeUyLP-/s200/DSCN3546+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnD65Zn-GyUvNcTb_7MEXjMSPm0Mw93L_za14DWF-0noL3sqVJf7o5sHYKfVH2rZ9bZCn5v_KcZD1rBG7Qg2qOFoelouGA_w71tjETAOnJxEhihvK3PF7smbJDhYzZENh2fFxXPQ_f4eYI/s1600/DSCN3552+(Small).JPG"><img style="WIDTH: 238px; HEIGHT: 110px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5537223071279811090" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnD65Zn-GyUvNcTb_7MEXjMSPm0Mw93L_za14DWF-0noL3sqVJf7o5sHYKfVH2rZ9bZCn5v_KcZD1rBG7Qg2qOFoelouGA_w71tjETAOnJxEhihvK3PF7smbJDhYzZENh2fFxXPQ_f4eYI/s200/DSCN3552+(Small).JPG" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-23110988074801410852010-11-08T07:59:00.000-08:002013-01-04T12:05:09.556-08:00Sand casting 6 parts in one flaskThis is the second aluminum pour I made for the 6 remaining ship parts. I ran a bit low on aluminum for one part so I made it again in a smaller flask. All of the parts looking good now its time for a bit of grinding and polish before final assembly.<br />
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height: 72px; width: 93px;" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-46112532582269586792010-11-07T13:43:00.000-08:002013-01-04T12:06:13.815-08:00Foundry Casting The Space Ship Saucer SectionAfter casting my aluminum star trek insignia I have decided to use it as a base stand for my next casting that is Cheyenne Class (star trek ship 1/1400 scale).<br />
In the next images you can see step by step how I made a sand mold for the ship saucer section.<br />
This project I am planning to make in two flasks one for the saucer section and the other flask I plan to cast 6 remaining parts in one go.<br />
This was also the first time I used my new <a href="http://flamingfurnace.blogspot.com/2010/10/aluminum-sand-rammer.html">aluminum sand rammer </a>that I made.<br />
The pattern I used is a solid plastic resin so I had to make it from one part instead of two halves.<br />
It is very easy with an object that is relatively flat all I had to do is clear the extra petrobond around the pattern and then cover it by filling the cope part.<br />
As for the sprue I used my babys wooden toy, it was perfect for this job.<br />
To prevent any molten metal over spilling on top of my sprue I used a sliced tin can (see image).<br />
I couldn't wait to open my flask and see how it looked but I had to let it cool down for 30 min.<br />
When I opened it I was delighted to see that the mold was full with very little porosity on the top saucer section and in a few more places but nothing that will effect its apperance.<br />
After all it is a space ship and there are many klingons and space debris out there.<br />
After cutting off the extra aluminum from the sprue and vent holes I did a bit of grinding and sanding and it started looking really good.<br />
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height: 79px; width: 102px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEideMq8VLAXTvh5-Uq5H6unIc7EqxLHqhhLepcb68Eg9nO01A3cxwXEkq4vHd9Gv02cGZy54RKROtxEqtcXKfcAFS0e359lpH-sf8Q42JUY1dJ3S1uE5yJ6SGW2r8DdKSLFsvCdxhGBNqT8/s1600/DSCN3422+(Small).JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5536930495990324290" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEideMq8VLAXTvh5-Uq5H6unIc7EqxLHqhhLepcb68Eg9nO01A3cxwXEkq4vHd9Gv02cGZy54RKROtxEqtcXKfcAFS0e359lpH-sf8Q42JUY1dJ3S1uE5yJ6SGW2r8DdKSLFsvCdxhGBNqT8/s200/DSCN3422+(Small).JPG" style="cursor: hand; height: 79px; width: 102px;" /></a> <span style="font-size: 0;"></span>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-69849912900598852802010-10-23T09:31:00.000-07:002010-11-03T05:26:26.666-07:00Aluminum Sand RammerThis is my second sand casting after a few experiments some successful other less with sea sand. last week I got 25kg Petrobond sand and I have to say their is no comperession and I am realy satisfied with the results.<br />This time I wanted to make an Aluminum Sand Rammer for my sand casting projects. I was thinking of making a pattern from wood and then I came across hard wood stair banister that was "waiting" in my shed for special occasion. Just by looking at it I could see the tool that I was looking for in my head. I cut it to a good working size and beveled one side for easy ramming of the flask corners. I also made a new wooden flask for this project.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgL97zcpCojHvHkc7p6aDmxLPANUOth1TcOScLgb5_QMe9UdvjEi2B73Oi7N-yHzWDmBgDQvGzwb4fnZONr1bngqH63qoP5Gvwm3vcLhEHdY3FtbtGNpG7-EkEoIcnVIVlc0rSR9qvwDn3y/s1600/DSCN3238+(Small).JPG"><img style="WIDTH: 125px; HEIGHT: 90px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531286256031007602" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgL97zcpCojHvHkc7p6aDmxLPANUOth1TcOScLgb5_QMe9UdvjEi2B73Oi7N-yHzWDmBgDQvGzwb4fnZONr1bngqH63qoP5Gvwm3vcLhEHdY3FtbtGNpG7-EkEoIcnVIVlc0rSR9qvwDn3y/s200/DSCN3238+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifksL6SIF7Wra3aAk0NTQcMhl0G0Xif9cJLV2wbiuszk016iakHCpWvirMhFIy_1rGCFD9-P391vyel47h3foFQ0C6eWhwxcb1FknQpL_LhPGzd1JV4luuv_LkSaoYmrln55ABUBUWzM8F/s1600/DSCN3241+(Small).JPG"><img style="WIDTH: 111px; HEIGHT: 87px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531286275155603026" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifksL6SIF7Wra3aAk0NTQcMhl0G0Xif9cJLV2wbiuszk016iakHCpWvirMhFIy_1rGCFD9-P391vyel47h3foFQ0C6eWhwxcb1FknQpL_LhPGzd1JV4luuv_LkSaoYmrln55ABUBUWzM8F/s200/DSCN3241+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkiRc19LzWhr8OjOfz36cjHkT46Wk45p4fprsJuaMQwipWbiIYohGiIjioocm6mNsOkLbPVwAN3j6T6o6VW3c77Q5D3ZnEI0Qb1V83PYyXNMQpTjzs2GejT0f_k_W80YPeNcYV814B36cQ/s1600/DSCN3252+(Small).JPG"><img style="WIDTH: 113px; HEIGHT: 87px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531286302876505890" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkiRc19LzWhr8OjOfz36cjHkT46Wk45p4fprsJuaMQwipWbiIYohGiIjioocm6mNsOkLbPVwAN3j6T6o6VW3c77Q5D3ZnEI0Qb1V83PYyXNMQpTjzs2GejT0f_k_W80YPeNcYV814B36cQ/s200/DSCN3252+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZvjeGa165N3QC06GXcgXPTql4bh5wWjYabJGl9Nv8b-muyP2JGkpAt5dvJ9aX-xYAUJYhMZ9SLLfCPJaR99e90DAX66czZp6lLTYyoaIQzJAq6jZT_uv2Ztp_5x0lnRbWkW35LF6E2tJz/s1600/DSCN3245+(Small).JPG"><img style="WIDTH: 111px; HEIGHT: 89px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531286279893745650" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZvjeGa165N3QC06GXcgXPTql4bh5wWjYabJGl9Nv8b-muyP2JGkpAt5dvJ9aX-xYAUJYhMZ9SLLfCPJaR99e90DAX66czZp6lLTYyoaIQzJAq6jZT_uv2Ztp_5x0lnRbWkW35LF6E2tJz/s200/DSCN3245+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg89K0RWGo9ea0-6JmnDgTovU6RDN5xMek-y_JmfNHQrEp6X2_Vuh0T7lZeUTwh87fATpJ7Ed1mP8yDr2atvvxMtYScqQfdLX0h5vwkQ0Z8jGyGfXuRSdSbL5dqrJ1Hct5dcjxmz7S7k2cl/s1600/DSCN3253+(Small).JPG"><img style="WIDTH: 122px; HEIGHT: 88px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531286311147441154" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg89K0RWGo9ea0-6JmnDgTovU6RDN5xMek-y_JmfNHQrEp6X2_Vuh0T7lZeUTwh87fATpJ7Ed1mP8yDr2atvvxMtYScqQfdLX0h5vwkQ0Z8jGyGfXuRSdSbL5dqrJ1Hct5dcjxmz7S7k2cl/s200/DSCN3253+(Small).JPG" /></a><br />I started by placing the pattern in the Drag and filling it with Petrobond ramming it well.<br />After drag was covered to the top I turned it over and used spoon to notch and smooth half way down the pattern. After smoothing it with the spoon I filled the Cope all the way up ramming it.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixCKDBbfN2yBADULT8CdmVizBN924hIIhyz0fG-L_6U_OKwKXjiRljGpIqmv3jnGIA07PP9YLGzt2B_GHDIQSTvgQaQM_BmWWZIag9_fEssYbU83nZ4h1jNo-Okkbm-3A5uwzCCTkJE-F2/s1600/DSCN3254+(Small).JPG"><img style="WIDTH: 142px; HEIGHT: 90px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531287658733259090" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixCKDBbfN2yBADULT8CdmVizBN924hIIhyz0fG-L_6U_OKwKXjiRljGpIqmv3jnGIA07PP9YLGzt2B_GHDIQSTvgQaQM_BmWWZIag9_fEssYbU83nZ4h1jNo-Okkbm-3A5uwzCCTkJE-F2/s200/DSCN3254+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiv8B6AFZBEHTggd2El9LybWC2YQDNhIzXQ146JK-LEp34uWMSObdrr5C7PKJumnXdpHMHdMUDIekpJk7CFWmW1KTcXSyxFUDCdjolTE7kxpho9qHtz8npGmp1R56CL6nxc3s-Kd3CT69Fo/s1600/DSCN3255+(Small).JPG"><img style="WIDTH: 111px; HEIGHT: 94px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531287660508848242" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiv8B6AFZBEHTggd2El9LybWC2YQDNhIzXQ146JK-LEp34uWMSObdrr5C7PKJumnXdpHMHdMUDIekpJk7CFWmW1KTcXSyxFUDCdjolTE7kxpho9qHtz8npGmp1R56CL6nxc3s-Kd3CT69Fo/s200/DSCN3255+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjR3ovSyLP8fB8zSrz9BuGLer9wscLD_Sk2DKwSW8nL3PKTP2NZ_SC-JKlimpIPKU9Vb_-ZsKVw8HHD5uMk_LWY3zjEV1k7NDkJWz42x1xiZ1UU46ryp-UjZff048Q-lHmSOjAwXw63C9yb/s1600/DSCN3257+(Small).JPG"><img style="WIDTH: 108px; HEIGHT: 92px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531287668035522402" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjR3ovSyLP8fB8zSrz9BuGLer9wscLD_Sk2DKwSW8nL3PKTP2NZ_SC-JKlimpIPKU9Vb_-ZsKVw8HHD5uMk_LWY3zjEV1k7NDkJWz42x1xiZ1UU46ryp-UjZff048Q-lHmSOjAwXw63C9yb/s200/DSCN3257+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKm02tY92G1Ws7ZzVOff77lphBcJlaGjwAN_v5OIptB2KRphGN1aCy4xZYLu9dGzlL918MfvJc0AyCYNMNLQk63a9mWp_Tzh7xjwkN7Yvi5btFoba6kzIh2oJ4G4q5E0ZD_MgrZ87kdiP1/s1600/DSCN3260+(Small).JPG"><img style="WIDTH: 135px; HEIGHT: 90px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531287669004201570" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKm02tY92G1Ws7ZzVOff77lphBcJlaGjwAN_v5OIptB2KRphGN1aCy4xZYLu9dGzlL918MfvJc0AyCYNMNLQk63a9mWp_Tzh7xjwkN7Yvi5btFoba6kzIh2oJ4G4q5E0ZD_MgrZ87kdiP1/s200/DSCN3260+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjg5WTasrLp7yeMPJMUdE2IfCH6pNm8x9ESNJvgbW6itOVzNXX3iP168i1ah_xF4JQ1CnFq30z-au42yI5wfk_e1cH3Ir9p2-OLC4nBfu6WjiY5o8jvqXgoLGsbD-GUXlNMVVe9oiapfpPf/s1600/DSCN3261+(Small).JPG"><img style="WIDTH: 120px; HEIGHT: 92px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531287674703811714" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjg5WTasrLp7yeMPJMUdE2IfCH6pNm8x9ESNJvgbW6itOVzNXX3iP168i1ah_xF4JQ1CnFq30z-au42yI5wfk_e1cH3Ir9p2-OLC4nBfu6WjiY5o8jvqXgoLGsbD-GUXlNMVVe9oiapfpPf/s200/DSCN3261+(Small).JPG" /></a><br />Next very gently I lifted the Cope and the pattern, Nerve wracking job. Beautiful result ;-)<br />I made pouring sprue to feed the molten aluminum in and small vent hole.<br />I used a clamp to keep Flask tight and poured the molten aluminum into the flask and the extra into the slim ingot tray that I welded.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfXAXKWYgs9nDByDMFQcs8loeD6boL0SZv95W3jECmKob6xy2UsOafYneB_dX9n2Mb5_Ji3262s6h8NcyzDlNMznP-1m-Nt_mb1FHBbVxG3_8Zo7kI5YQ5dbnOcoM-wmX41C2bolwKWeli/s1600/DSCN3263+(Small).JPG"><img style="WIDTH: 114px; HEIGHT: 91px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531291037395762802" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfXAXKWYgs9nDByDMFQcs8loeD6boL0SZv95W3jECmKob6xy2UsOafYneB_dX9n2Mb5_Ji3262s6h8NcyzDlNMznP-1m-Nt_mb1FHBbVxG3_8Zo7kI5YQ5dbnOcoM-wmX41C2bolwKWeli/s200/DSCN3263+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnKGwidHCVIp3bQxlUu2O40dI4IaO82hJ15AlbV_YxxIHIG1MI-_7NVOrkN2Ol42vmXOq-9xoT83tqxo2JvX9bFilMcIMjBNqbpjIQFuzrom_1_z19KNxb64cIIJGgp95zS9kbO9dc-WsX/s1600/DSCN3265+(Small).JPG"><img style="WIDTH: 116px; HEIGHT: 92px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531291037026634866" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnKGwidHCVIp3bQxlUu2O40dI4IaO82hJ15AlbV_YxxIHIG1MI-_7NVOrkN2Ol42vmXOq-9xoT83tqxo2JvX9bFilMcIMjBNqbpjIQFuzrom_1_z19KNxb64cIIJGgp95zS9kbO9dc-WsX/s200/DSCN3265+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhod1FffRNSEAfVmyzDzVjMiyeY7QJBxCk2HrpkdvLXzYzmwFaH8PLs788x6Wq0ryNBzWL5rWFHeBoE3EBLi6DwXI1yHaKYdh-4s399SZIuhA0FiYtdxno-qM8lWgQI-ZPZkiuhw78BRd31/s1600/DSCN3271+(Small).JPG"><img style="WIDTH: 129px; HEIGHT: 90px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531291042338388578" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhod1FffRNSEAfVmyzDzVjMiyeY7QJBxCk2HrpkdvLXzYzmwFaH8PLs788x6Wq0ryNBzWL5rWFHeBoE3EBLi6DwXI1yHaKYdh-4s399SZIuhA0FiYtdxno-qM8lWgQI-ZPZkiuhw78BRd31/s200/DSCN3271+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqMyd2yy2Ce_aq_1g2Svm6TccvgAvDInpXdIZviOUy2gEmcIx3CW_fiyAycwFjud57V7FoTmF9hwlmeaEcIOz-cbLF5SruyLjAVrHiP1eDL__SsaX_QiNYfvlgwfrK1Sd5F4KPWdQ_A_Th/s1600/DSCN3285+(Small).JPG"><img style="WIDTH: 131px; HEIGHT: 91px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531291055901617858" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqMyd2yy2Ce_aq_1g2Svm6TccvgAvDInpXdIZviOUy2gEmcIx3CW_fiyAycwFjud57V7FoTmF9hwlmeaEcIOz-cbLF5SruyLjAVrHiP1eDL__SsaX_QiNYfvlgwfrK1Sd5F4KPWdQ_A_Th/s200/DSCN3285+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGXhvOvu3w1344vUyEug1ZFFHxBpokgQSHVm0CKdLPD02uSwI4saTLYt8HxI9IEga0rWzymfqGbyfhdEoJ1YIv-m4uAcjmIMIbN0BDB750aLImZ4iTjtjhlWRwxSMl8mcyY17uY4BqbOtw/s1600/DSCN3282+(Small).JPG"><img style="WIDTH: 120px; HEIGHT: 86px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531291047499979522" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGXhvOvu3w1344vUyEug1ZFFHxBpokgQSHVm0CKdLPD02uSwI4saTLYt8HxI9IEga0rWzymfqGbyfhdEoJ1YIv-m4uAcjmIMIbN0BDB750aLImZ4iTjtjhlWRwxSMl8mcyY17uY4BqbOtw/s200/DSCN3282+(Small).JPG" /></a><br />Now this is the hardest part, WAITING for the metal to cool before opening the flask...<br />Still a bit hot but the result of my second sand casting amazed me, BEAUTIFUL aluminum sand rammer. In the image you can see the Parting line between the Cope and Drag.<br />After light cleaning I have a new tool ready for use.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKZqS8xXfTAz_2fW1_Cv3w44ZFzYsyH4iNHYceRDFYSpqsuk5jRVbVEJNhgsKzKwdqDErL3RmZev-fTKKfetXIAEG1-PnH6z35pT54bdZ7JNyEcLc37MNHrEDhBic5gZl8QHJym9udggjD/s1600/DSCN3286+(Small).JPG"><img style="WIDTH: 138px; HEIGHT: 104px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531292622544398338" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKZqS8xXfTAz_2fW1_Cv3w44ZFzYsyH4iNHYceRDFYSpqsuk5jRVbVEJNhgsKzKwdqDErL3RmZev-fTKKfetXIAEG1-PnH6z35pT54bdZ7JNyEcLc37MNHrEDhBic5gZl8QHJym9udggjD/s200/DSCN3286+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVMusap5Mms8K_AL7QCwFE9HicXXQuqRK3uouD41eVg5KfCUVwQi5IMdGlOyJu2Hw0G0euBddgqAMYzWpZMiJZV3bfH8NtaEF_oq7_TcznCae1WljANWNvtJ3pbh-b_jBlflteSRJDIN-m/s1600/DSCN3292+(Small).JPG"><img style="WIDTH: 156px; HEIGHT: 102px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531292632555131986" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVMusap5Mms8K_AL7QCwFE9HicXXQuqRK3uouD41eVg5KfCUVwQi5IMdGlOyJu2Hw0G0euBddgqAMYzWpZMiJZV3bfH8NtaEF_oq7_TcznCae1WljANWNvtJ3pbh-b_jBlflteSRJDIN-m/s200/DSCN3292+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgo4JufQOv_O7xrzI6FaTPM_w6znyI6giBHgdfvd5bx266Z7F9Y1yAe0P-3OIL88qsGte2eh0y_p6JXbB2lNoIbJ9kTDEHtWvQLXKM_s3vUHttlnT-Icm_x_7vGxy7hYz_Ja8DYhu8P-5zl/s1600/DSCN3294+(Small).JPG"><img style="WIDTH: 153px; HEIGHT: 106px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531292636555994626" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgo4JufQOv_O7xrzI6FaTPM_w6znyI6giBHgdfvd5bx266Z7F9Y1yAe0P-3OIL88qsGte2eh0y_p6JXbB2lNoIbJ9kTDEHtWvQLXKM_s3vUHttlnT-Icm_x_7vGxy7hYz_Ja8DYhu8P-5zl/s200/DSCN3294+(Small).JPG" /></a><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7s0wyL_MlDREgbGe1G1EZZBv-MPb3GX7lVB8jyHAL4aoleB_2ypwj_RvfXIjqu7R9mDMZc-8WExr9l-175VcqRowCBz9mzEXpFWdj_YnjQw_z5DY_cjny5uUfs8b-wKT6T5LlUtzDeHQt/s1600/DSCN3300+(Small).JPG"><img style="WIDTH: 199px; HEIGHT: 126px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531294848212898818" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7s0wyL_MlDREgbGe1G1EZZBv-MPb3GX7lVB8jyHAL4aoleB_2ypwj_RvfXIjqu7R9mDMZc-8WExr9l-175VcqRowCBz9mzEXpFWdj_YnjQw_z5DY_cjny5uUfs8b-wKT6T5LlUtzDeHQt/s200/DSCN3300+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZpKgbNgyDsoiFilQeEUUogsiBpE_qpbpc16U-A10I65CP41X2WeS3DkaoEEMaoxzIrjC2BRdyc_oV0mjYn5IOOO7zqQp2JTsw52U9HTbjSSUMy6qPVTj4vLYSSEudhjdRhwuLrkbpBe9p/s1600/DSCN3297+(Small).JPG"><img style="WIDTH: 174px; HEIGHT: 129px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531294841649076082" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZpKgbNgyDsoiFilQeEUUogsiBpE_qpbpc16U-A10I65CP41X2WeS3DkaoEEMaoxzIrjC2BRdyc_oV0mjYn5IOOO7zqQp2JTsw52U9HTbjSSUMy6qPVTj4vLYSSEudhjdRhwuLrkbpBe9p/s200/DSCN3297+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLoTRVH3wnXMw0zUyK51ZeDXJ9nG6YL4VCJM-C7eUeiwxX-fzN9N92M5DvDNuCPz3uTG1hZS3rORex7wJ2E4HNd_SxWU1Pafe3tDCOp4dU1klwkvaI4oYETm6736eQD1wM1TjMcu9RzjDy/s1600/DSCN3302+(Small).JPG"><img style="WIDTH: 117px; HEIGHT: 130px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5531294851332474866" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLoTRVH3wnXMw0zUyK51ZeDXJ9nG6YL4VCJM-C7eUeiwxX-fzN9N92M5DvDNuCPz3uTG1hZS3rORex7wJ2E4HNd_SxWU1Pafe3tDCOp4dU1klwkvaI4oYETm6736eQD1wM1TjMcu9RzjDy/s200/DSCN3302+(Small).JPG" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-84868594014929575432010-10-20T09:33:00.000-07:002013-01-04T12:06:46.488-08:00Sand casting (experiment)I started my first sand casting as an experimant using sea sand. After making a simple pattern and using only half a flask it didn't really work out as you can see in my image. The best part about aluminum it could be remelted again and again, so I broke the casting and remelted it back into ingots.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOx2puAPh4If0gisHwnJCfxqrqFMg8ucC2IESOBDSojwuqOT9cO8o-0c_SnFzLNuIdX6IWkp6HRLvpQvdCS9iyKwRnA28_8T0gKsQfUatlQKO_23ZTKkyAXsb1TZ9Qa4q3r8MjYAYwFx_f/s1600/flamingfurnace.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5531209415222388946" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOx2puAPh4If0gisHwnJCfxqrqFMg8ucC2IESOBDSojwuqOT9cO8o-0c_SnFzLNuIdX6IWkp6HRLvpQvdCS9iyKwRnA28_8T0gKsQfUatlQKO_23ZTKkyAXsb1TZ9Qa4q3r8MjYAYwFx_f/s200/flamingfurnace.JPG" style="cursor: hand; height: 88px; width: 120px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijeeVrRNvUyaZ4Y469rwSMplDaiMwhNi8c62Z4r91yWjZxbQt6ry_bfwmzgpemLTMGuq8gdpgPYUpOd15pUgLYQD3jQgXTy4hD9YQnSsMqjJPUpKPD6RO3jLuT4lqOm2mrewDikB_obSfj/s1600/seasandcasting.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5531209425006083746" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijeeVrRNvUyaZ4Y469rwSMplDaiMwhNi8c62Z4r91yWjZxbQt6ry_bfwmzgpemLTMGuq8gdpgPYUpOd15pUgLYQD3jQgXTy4hD9YQnSsMqjJPUpKPD6RO3jLuT4lqOm2mrewDikB_obSfj/s200/seasandcasting.JPG" style="cursor: hand; height: 88px; width: 115px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEPBEE72t9pMz8A4wQQZjtxskCn1EAZph6UgXN7uHSFYgf4VveNURI2oo74aNdfb_3mJP8Iwqyr8y6bShPBjfPEfGn5xL1kvQLwe6dXu_1nXz9xCbHYW7_lkxbNPT_rthK6tNP-GYn1shE/s1600/experimentsandcastin.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5531209412755359362" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEPBEE72t9pMz8A4wQQZjtxskCn1EAZph6UgXN7uHSFYgf4VveNURI2oo74aNdfb_3mJP8Iwqyr8y6bShPBjfPEfGn5xL1kvQLwe6dXu_1nXz9xCbHYW7_lkxbNPT_rthK6tNP-GYn1shE/s200/experimentsandcastin.JPG" style="cursor: hand; height: 90px; width: 118px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWm6aI2pPCkCC_AsZtAgcdoWNgShupXTa2b1BfsH4gNk-czzcJIrNygnQU2HxAFM9mIVtpvzwgdjz89yTEsA0qVbZmWS9wfYEZsnv4ME6EtduW2_nqlsC3ZCtweD-O4x_x3KaKmuXSsUy1/s1600/brokenpattern.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5531209408856288562" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWm6aI2pPCkCC_AsZtAgcdoWNgShupXTa2b1BfsH4gNk-czzcJIrNygnQU2HxAFM9mIVtpvzwgdjz89yTEsA0qVbZmWS9wfYEZsnv4ME6EtduW2_nqlsC3ZCtweD-O4x_x3KaKmuXSsUy1/s200/brokenpattern.JPG" style="cursor: hand; height: 92px; width: 104px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBP-naUEo-gATpolGjSgaDqQTrnJcNAjwRjqjTGILMqSzibs1R8LqWGrJr2v1Nyc3L94YDj-ZdJ-5N86kJIifa9r32By7t4t74yhvLNLDLGlSt171pB98bJ_r4kMuATbM-hgQyOQaLy1uy/s1600/my+aluminum+life+cycle+(Large).JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5530440552225518354" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBP-naUEo-gATpolGjSgaDqQTrnJcNAjwRjqjTGILMqSzibs1R8LqWGrJr2v1Nyc3L94YDj-ZdJ-5N86kJIifa9r32By7t4t74yhvLNLDLGlSt171pB98bJ_r4kMuATbM-hgQyOQaLy1uy/s200/my+aluminum+life+cycle+(Large).JPG" style="cursor: hand; height: 93px; width: 96px;" /></a><br />This time I bought PETROBOND sand, I got one bag of 25kg it is a bit expensive but amazingly easy to work with and the results speak for them self.<br />My first proper obeject I made was a Star Trek federation insignia, the original pattern is made from plastic resin that I got a few years ago in a custom model kit box.<br />The first pour was very good but small part in the cavity didn't fill all the way so I tried again this time using only sprue hole without vent hole and it was perfect.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggeRdQBwQCpvqOgUm6sHO2abfcCJROHU7KZQCVSr7d8o3FPot010uiPp5sR-LV1bT4zqnN4BO8R96OGSDQo2TZRk6rFm3wD6xiLoxl17Hxuz_6apF5-M0dI0i6-swrYt89b_LZkXyUutec/s1600/flask.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5531212566692087170" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggeRdQBwQCpvqOgUm6sHO2abfcCJROHU7KZQCVSr7d8o3FPot010uiPp5sR-LV1bT4zqnN4BO8R96OGSDQo2TZRk6rFm3wD6xiLoxl17Hxuz_6apF5-M0dI0i6-swrYt89b_LZkXyUutec/s200/flask.JPG" style="cursor: hand; 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height: 70px; width: 91px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9rP9igKG3toBCn8Bxa31tZhPuQ5CtXlzptYsjdCm2Y7raRO5jNfY7Sk69p35MrHSUuyr0VPcaEOyFZRmhN7yIZ0tzxylmEtx-0HUumgaXFCuBTorxJK8P82SZeXiyXt8DHfjVJK2Iir7y/s1600/DSCN3207+(Small).JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5531211908077813042" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9rP9igKG3toBCn8Bxa31tZhPuQ5CtXlzptYsjdCm2Y7raRO5jNfY7Sk69p35MrHSUuyr0VPcaEOyFZRmhN7yIZ0tzxylmEtx-0HUumgaXFCuBTorxJK8P82SZeXiyXt8DHfjVJK2Iir7y/s200/DSCN3207+(Small).JPG" style="cursor: hand; height: 71px; width: 89px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2G2uVbYfdu_YE88NdAzFw7vFxX45W7l4EI5i-qnJn2yKRBaOH604xuulozJ0BKrzFY1A4NXnzpniYOo2OockxiJIWaboZl_BXZ-WF3SOUdiL68yaWwr1rgz6n9LUevjWjbf15CO5ZNFip/s1600/sandcastinopen.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5531212577799757074" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2G2uVbYfdu_YE88NdAzFw7vFxX45W7l4EI5i-qnJn2yKRBaOH604xuulozJ0BKrzFY1A4NXnzpniYOo2OockxiJIWaboZl_BXZ-WF3SOUdiL68yaWwr1rgz6n9LUevjWjbf15CO5ZNFip/s200/sandcastinopen.JPG" style="cursor: hand; 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height: 71px; width: 97px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEpcAJk6BR52EZKzfLJRL6d86kf0m57BiX6HgWuJ26k04n3Szx1oTbuNTUkUjgiBJHBNrd0BkOhtXbM55Zh6eDwys7MaZn1cJpgk6NWLF4qKwyXG6SuRbqiwmtl0eQxmL_8UXSYEDhFrpt/s1600/patterngoodandbad.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5531212571246356178" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEpcAJk6BR52EZKzfLJRL6d86kf0m57BiX6HgWuJ26k04n3Szx1oTbuNTUkUjgiBJHBNrd0BkOhtXbM55Zh6eDwys7MaZn1cJpgk6NWLF4qKwyXG6SuRbqiwmtl0eQxmL_8UXSYEDhFrpt/s200/patterngoodandbad.JPG" style="cursor: hand; height: 73px; width: 87px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgG-MW22Wx1vrS_dBSx3AE4te7CIpXFh6AThO-WdjZTOh3nKdcIu0X-Vhfassl8UQNwsFQY9Bf7oY08HCllexIqC5CTy9nvfzdkiB6WlVag6Gga8v9AQyt0X641KvIefwHLjlPvSqZQOGBw/s1600/aluminumstartrek.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5531210948623666050" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgG-MW22Wx1vrS_dBSx3AE4te7CIpXFh6AThO-WdjZTOh3nKdcIu0X-Vhfassl8UQNwsFQY9Bf7oY08HCllexIqC5CTy9nvfzdkiB6WlVag6Gga8v9AQyt0X641KvIefwHLjlPvSqZQOGBw/s200/aluminumstartrek.JPG" style="cursor: hand; height: 73px; width: 90px;" /></a>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-81853599475352427792010-10-07T15:04:00.002-07:002013-02-22T08:29:04.710-08:00Aluminum parts and ingots<br />
When we look around we can see aluminum all over the place casted into different objects that we use daily. I took a few images of aluminum parts that I melted in my foundry and turned them into aluminum ingots. I will re-use the ingots for my sand castnig projects. I also separate the aluminum alloys and mark on the ingots what object it was before.<br />
In my images I melted nut cracker, lock parts, cooker parts, door handles, tap handles,tripod legs, scotter parts (resize to fit into the crucible), aluminun brackets, toy car, glasses stand , toilet hinges, wine bottle cork and ladder parts. (Some parts in this images are pot metal)<br />
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<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCN0wFJSsinQY_eyeYsiFdUlMQxSj6OMTzvJGGs6wcqIv62ByvY_iKlBjcTJzXDmjwZAQdu9mx4aiTfyMUIsZ6pwDQMbWokPyXREML7oJCGPI3s2esxsFi-oknJXT-O0reADfXQ4ya60x2/s1600/DSCN3329+(Small).JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5525431415467089522" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCN0wFJSsinQY_eyeYsiFdUlMQxSj6OMTzvJGGs6wcqIv62ByvY_iKlBjcTJzXDmjwZAQdu9mx4aiTfyMUIsZ6pwDQMbWokPyXREML7oJCGPI3s2esxsFi-oknJXT-O0reADfXQ4ya60x2/s200/DSCN3329+(Small).JPG" style="cursor: pointer; height: 83px; width: 128px;" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbPkSjIQ_q4NpjIUygxElOjNFhyFvAKp8rxG35PMAiu22h93dCQXUAw4WwLA98rnWvKoxwG9-Pb0MXGVrdOv1DK6Rv82Cb5Dt6Gm3EUomwKjADm4u0kx6djDZFmPkBuZ5yPIvS8qAdb3SB/s1600/DSCN2875+(Small).JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5525431348357711618" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbPkSjIQ_q4NpjIUygxElOjNFhyFvAKp8rxG35PMAiu22h93dCQXUAw4WwLA98rnWvKoxwG9-Pb0MXGVrdOv1DK6Rv82Cb5Dt6Gm3EUomwKjADm4u0kx6djDZFmPkBuZ5yPIvS8qAdb3SB/s200/DSCN2875+(Small).JPG" style="cursor: pointer; height: 81px; width: 129px;" /></a></td><td><a href="http://4.bp.blogspot.com/_JEie8lPwjWc/TK5GeTseAzI/AAAAAAAABCA/lLXq2s6BlLQ/s1600/DSCN2604+(Small).JPG"><span style="font-size: 0px;"></span></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHVr5u0cZr5k4W8f3IKn-MVVZuljGp86wTFGgufnZ8jN6MY7x3tB6tlQNgD4DdFzCY0hmG_4ku3XMeDRrW8L3VgJrsET13rySZmfCIpvoxEKWOqK8uD805ecBv6gqPt2rdOu7fYBws_cqB/s1600/DSCN2571+(Small).JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5525431223606676450" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHVr5u0cZr5k4W8f3IKn-MVVZuljGp86wTFGgufnZ8jN6MY7x3tB6tlQNgD4DdFzCY0hmG_4ku3XMeDRrW8L3VgJrsET13rySZmfCIpvoxEKWOqK8uD805ecBv6gqPt2rdOu7fYBws_cqB/s200/DSCN2571+(Small).JPG" style="cursor: pointer; height: 79px; width: 105px;" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjm64mtV2klCRApSunwsjuVGsY8HDYh3xvEYcJFdnmjzTeHSsBk0j_qH8X6DHJnt6g2bqgOql2N_ZykRah1uuAHjtGhLTzV9owFrLDFMrj40Heg6tox4Ai7KkY-KK6S_Hsitrrw6Ad4ucLq/s1600/DSCN2552+(Small).JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5525431173127115666" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjm64mtV2klCRApSunwsjuVGsY8HDYh3xvEYcJFdnmjzTeHSsBk0j_qH8X6DHJnt6g2bqgOql2N_ZykRah1uuAHjtGhLTzV9owFrLDFMrj40Heg6tox4Ai7KkY-KK6S_Hsitrrw6Ad4ucLq/s200/DSCN2552+(Small).JPG" style="cursor: pointer; height: 78px; width: 96px;" /></a></td><td><img alt="" border="0" id="BLOGGER_PHOTO_ID_5525431054737036370" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMPvBcQVD5CdeuXyYCUDxKgjrJsloJSY8wBHES055m9UQ3WSW_BVgBax0faniU6WjfUbL0gl-umDPoFXMOp0PyWVvqv_XY1DDj9jUcNqc-AVWD_Oav6ZIXKL6lKN37_eLoQJqoLtnt8Nib/s200/DSCN2515+(Small).JPG" style="cursor: pointer; height: 78px; width: 126px;" /></td></tr>
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<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT4pEMPS5hRXDxytZhdFhZ_hGc9iE_t1wUnqeq3RTEvDDBy_SEFbOvcxDF8y5155R1vyk5_5NBsPKsE4XELlXqWEecvkPv6mfwR6AtmVA1YAUjUjOhD0gVTFkxyhwT6EASp12oVcdo3t5L/s1600/DSCN2411+(Small).JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5525430929915036050" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT4pEMPS5hRXDxytZhdFhZ_hGc9iE_t1wUnqeq3RTEvDDBy_SEFbOvcxDF8y5155R1vyk5_5NBsPKsE4XELlXqWEecvkPv6mfwR6AtmVA1YAUjUjOhD0gVTFkxyhwT6EASp12oVcdo3t5L/s200/DSCN2411+(Small).JPG" style="cursor: pointer; height: 82px; width: 131px;" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPXUbRs7Bfcv-XUL9cwgwbQ9SIQKRgF05q21uGaINnPbwAEDbmtVguwAXfA7emkU0qEDWacQ2wX_q9fyRC1dkupcwTzoPZBPDbtOOZrLX9LmU1ySA5yCN_pswWEZAgt00HV6cjIRqla2fg/s1600/DSCN2412+(Small).JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5525430992073111394" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPXUbRs7Bfcv-XUL9cwgwbQ9SIQKRgF05q21uGaINnPbwAEDbmtVguwAXfA7emkU0qEDWacQ2wX_q9fyRC1dkupcwTzoPZBPDbtOOZrLX9LmU1ySA5yCN_pswWEZAgt00HV6cjIRqla2fg/s200/DSCN2412+(Small).JPG" style="cursor: pointer; height: 79px; width: 129px;" /></a></td><td><img alt="" border="0" id="BLOGGER_PHOTO_ID_5525435478392609426" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLJ74pDluwpbRij2ZIUWqTdoAo_YVwiPg5sVJi95jZjH9pJlxpgneBnyQ0-EFN06QASScrN4L7BotrEXXSHEk4iPnfxdzRfcHx5gp3LkdQXoS8t_1B9WIw29WJyZAvlX-M-puq5qgqiUdh/s200/DSCF2634+(Small).JPG" style="cursor: pointer; height: 76px; width: 131px;" /></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjh-ufthX3H9beh8YFgpVgPy7fWnnV4VjO0blOOCNvGuhfb6KDSNskhbpXivp-8TVrgX4eYvjJpxbszLaRRIdHKGc1AEcmg6FsIbUCwQ1e1JJF7krcuBEQ9HhVXCp8bk1kKM2ZvQpnsqJzP/s1600/DSCN3655+(Small).JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5525434059155122594" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjh-ufthX3H9beh8YFgpVgPy7fWnnV4VjO0blOOCNvGuhfb6KDSNskhbpXivp-8TVrgX4eYvjJpxbszLaRRIdHKGc1AEcmg6FsIbUCwQ1e1JJF7krcuBEQ9HhVXCp8bk1kKM2ZvQpnsqJzP/s200/DSCN3655+(Small).JPG" style="cursor: pointer; height: 83px; width: 106px;" /></a></td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgThQ1Yvv65azvF4KnRzT9OncV_o2jVUD2LiDh1RqRbzWkrMGqaU58gquBFkBDsn73QPRbZfccnxtgEsQgFdHVViLME-cS8nc6bed9uVZtw4h-EiXCcT7E29PdoiN0Eq_pvi38funuS-GH/s1600/DSCN3658+(Small).JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5525434124557129490" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgThQ1Yvv65azvF4KnRzT9OncV_o2jVUD2LiDh1RqRbzWkrMGqaU58gquBFkBDsn73QPRbZfccnxtgEsQgFdHVViLME-cS8nc6bed9uVZtw4h-EiXCcT7E29PdoiN0Eq_pvi38funuS-GH/s200/DSCN3658+(Small).JPG" style="cursor: pointer; height: 82px; width: 97px;" /></a></td></tr>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpIAyj6ULsIoi5mJrdYOPcJ9sPGreq3I3jzlrGShAawwVXe22aSfYzj7ytsNUEzBwjRyQ1KfaeRaFYTdJtZw9KR9ExW_uDY3AsU6PyWQ0L2LNyvgA_8u8sv_nzWhgBBGXmUxPkdeHK9UfQ/s1600/aluminum+ingots.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5525437927255946018" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpIAyj6ULsIoi5mJrdYOPcJ9sPGreq3I3jzlrGShAawwVXe22aSfYzj7ytsNUEzBwjRyQ1KfaeRaFYTdJtZw9KR9ExW_uDY3AsU6PyWQ0L2LNyvgA_8u8sv_nzWhgBBGXmUxPkdeHK9UfQ/s200/aluminum+ingots.JPG" style="cursor: pointer; height: 76px; width: 125px;" /></a> The best aluminum alloys to re-use again for sand casting are probably parts such as car pistons, engine head, transmission bell housing etc'.<br />
In my image you can see a piston that I melted into ingots, to starting its new "life cycle".<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqxPfRkChAPB38UkQAQy0L3dTXvnh99q76y2mp9r82-oRHH2I0sENqPo_l0JAF9j_X2Aakmv58QKGWHno2o-XC9yvCmWRC_ObApzwDQKb3AjMVY77oGmvgbeNb8MocdJ4PDAiHnLbuj7VB/s1600/aluminum+piston+melting.JPG" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5566872760795379378" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqxPfRkChAPB38UkQAQy0L3dTXvnh99q76y2mp9r82-oRHH2I0sENqPo_l0JAF9j_X2Aakmv58QKGWHno2o-XC9yvCmWRC_ObApzwDQKb3AjMVY77oGmvgbeNb8MocdJ4PDAiHnLbuj7VB/s200/aluminum+piston+melting.JPG" style="cursor: pointer; height: 160px; width: 200px;" /></a> <a href="http://3.bp.blogspot.com/_JEie8lPwjWc/TUHHqRfWM-I/AAAAAAAABrE/quWzo0jKyF8/s1600/aluminum%2Bparts.jpg" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}"><span style="font-size: 0px;"></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjC2EnmQ200YSQim7sLbNBMOgoLGw7n45SW1CRFNLLz-gO2gxcxMREw26r4hO48NFKKJUf2AYHLVGGOekKCpkMzgTaCHzNj4btgrcJk0iNbWFRakbqwLq3oV659KngqzD9OUCXDXhXOev-j/s1600/aluminum+parts.JPG" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5566954635514935250" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjC2EnmQ200YSQim7sLbNBMOgoLGw7n45SW1CRFNLLz-gO2gxcxMREw26r4hO48NFKKJUf2AYHLVGGOekKCpkMzgTaCHzNj4btgrcJk0iNbWFRakbqwLq3oV659KngqzD9OUCXDXhXOev-j/s200/aluminum+parts.JPG" style="cursor: pointer; height: 160px; width: 200px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLYlgSCZiq-_OWipc37v8gLab8mfkoc_SPGYIHprJAahtXKhgcxVKwniELgQLE5qJS1A-rzKJjxfq44fttKuTCPnfQ6IWRsvojF4bQWcICQ5Z3r8G1oY0TcZPODldxKN7oNRjpKdEftJjr/s1600/aluminum+scooter+sprue+riser+wheel.JPG" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5568347193420826930" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLYlgSCZiq-_OWipc37v8gLab8mfkoc_SPGYIHprJAahtXKhgcxVKwniELgQLE5qJS1A-rzKJjxfq44fttKuTCPnfQ6IWRsvojF4bQWcICQ5Z3r8G1oY0TcZPODldxKN7oNRjpKdEftJjr/s200/aluminum+scooter+sprue+riser+wheel.JPG" style="cursor: pointer; height: 161px; width: 194px;" /></a><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjB39-Y6bGj36qZh_b7cmNyl4zUFY4Vx7wah_mmHzYkSpTqBNJktmxorhQ3B9Qf9rBmnAyqphA5LSdTXjHIEEtBrpkrys7HLyT3zpOaNMaJ5vmcCl6gUtvUiAVD31MMDLQknIHhvRpKJXwC/s1600/aluminum+scooter.JPG" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5568347193997680962" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjB39-Y6bGj36qZh_b7cmNyl4zUFY4Vx7wah_mmHzYkSpTqBNJktmxorhQ3B9Qf9rBmnAyqphA5LSdTXjHIEEtBrpkrys7HLyT3zpOaNMaJ5vmcCl6gUtvUiAVD31MMDLQknIHhvRpKJXwC/s200/aluminum+scooter.JPG" style="cursor: pointer; height: 150px; width: 200px;" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhF4sbBhO0Q-PQMC-y3Jr41WAJppO-bUosUVW42pDHkRf2p6NPZf8GB3U6WdQedC0sDbCg6ls8Jusi7Q7LLehqZvyS0DAqlAvzxwp8v-8bd6Lx1xDhefa-LuGdNaIvj8v1y1hhZljqGaf_8/s1600/aluminum+door+parts.JPG" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5568348471639758642" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhF4sbBhO0Q-PQMC-y3Jr41WAJppO-bUosUVW42pDHkRf2p6NPZf8GB3U6WdQedC0sDbCg6ls8Jusi7Q7LLehqZvyS0DAqlAvzxwp8v-8bd6Lx1xDhefa-LuGdNaIvj8v1y1hhZljqGaf_8/s200/aluminum+door+parts.JPG" style="cursor: pointer; height: 150px; width: 200px;" /></a> <img alt="" border="0" id="BLOGGER_PHOTO_ID_5568349290880792994" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYhTwX29hk60TCMdYMTJOFAnHp0zNHQ5WF52YvLxeC3ruPqOwanS-mPF4SWCAEwZAtEhubHSRMF3dW1wp8MQYIGunBm9EPi4JK7Ox5qReLohWLXHGJmURoudLOvgjrbuxuEkRRfCJdib3V/s200/aluminum+brackets.JPG" style="cursor: pointer; height: 150px; width: 200px;" /><br />
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FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-36186637757952648092010-10-06T09:22:00.000-07:002011-09-04T13:53:17.216-07:00My second homemade foundryThis is my second foundry and I made it from empty gas cylinder. First I made sure the cylinder is empty then I drilled 2 holes. One hole to fill the cylinder with water the other as air hole makes it easy to empty the water and to fill it again.
<br />After all gas is gone I marked where I want to cut and used my small grinder for that job. When I cut the cylinder I had it full of water, just to be on the safe side. It took me less then 10min to cut the cylinder handle, top nozzle and cylinder top including grinding the rough bits of metal.
<br />It is a good idea to mark lines over cutting so later on when welding, the lid will fitt well.
<br />When using the grinder It is recommanded wearing eye and ears protection.
<br /><span style="color:#ff0000;"><strong>If you don't know what you are doing take it to a professional. Misuse of pressured gas cylinders can cause injury and even fatalities.
<br />This is not an instruction or a guide how to do it, I am sharing with you how I used a gas cylinder based on my own experience and knowledge.
<br />Anyone who attempts this he/she will do it on their own risk,</strong></span>
<br /><span style="color:#ff0000;"><strong><u>I will not be liable for any injuries/damage in anyway</u>.</strong> </span>
<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3E9Ah_sVYgS8TmZmCtWlY0Wks1n-xuTcV3sqFFOgAr8xUbykPuoCpYo5DBYAywAEbuACpaFm4Jss0X85cZmcRxo4f7FuNK1qeHXYcZbqYxjV-onUdKqUhwzPEeMyWc7khLhcqmOkWbAV_/s1600/DSCN2558+(Small).JPG"><img style="WIDTH: 115px; HEIGHT: 78px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524972726064417682" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3E9Ah_sVYgS8TmZmCtWlY0Wks1n-xuTcV3sqFFOgAr8xUbykPuoCpYo5DBYAywAEbuACpaFm4Jss0X85cZmcRxo4f7FuNK1qeHXYcZbqYxjV-onUdKqUhwzPEeMyWc7khLhcqmOkWbAV_/s200/DSCN2558+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHgUysD5770LOY8Ergnqtc9R0TwFcD4c4jPFNLRz0WthmFFxuBIKZecXjclokOjUezu2bVItcuFLWSuhIR8InwfX6tVseqNGjIxu0HSx8tl5PaLnFVHyD2txDMjtOuknTRLhXBEvsM91LO/s1600/DSCN2578+(Small).JPG"><img style="WIDTH: 101px; HEIGHT: 85px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524973085886587922" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHgUysD5770LOY8Ergnqtc9R0TwFcD4c4jPFNLRz0WthmFFxuBIKZecXjclokOjUezu2bVItcuFLWSuhIR8InwfX6tVseqNGjIxu0HSx8tl5PaLnFVHyD2txDMjtOuknTRLhXBEvsM91LO/s200/DSCN2578+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEha9tcIVOVzKIPIlbvDBN41jUlxN4QWtfqisTllSBsiiGtTUfVipYv4zM8Pxo9OHQB9yE9VC3uOZ8qF6fNfP114JROHkWXVYS_diwyHySIQquZdif0kIro0PbEgmh0MGwYrIqX4C0OfCzMV/s1600/DSCN2579+(Small).JPG"><img style="WIDTH: 100px; HEIGHT: 80px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524973704507389538" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEha9tcIVOVzKIPIlbvDBN41jUlxN4QWtfqisTllSBsiiGtTUfVipYv4zM8Pxo9OHQB9yE9VC3uOZ8qF6fNfP114JROHkWXVYS_diwyHySIQquZdif0kIro0PbEgmh0MGwYrIqX4C0OfCzMV/s200/DSCN2579+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgfj-pTy2itqUzeZrUM6cHwp7rGJQ-UCF-extdU9jEkCM73zLHoGVuTH_baRG2xksCFEJqNhJFJfSVZrCdwUtQPRwbmJnMjBAxZUJRaPN_-jJ9oZPXckUfEKDqw6uZ2Fsyufa9-tOeEZAy/s1600/DSCN2608+(Small).JPG"><img style="WIDTH: 100px; HEIGHT: 80px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524974993788615906" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgfj-pTy2itqUzeZrUM6cHwp7rGJQ-UCF-extdU9jEkCM73zLHoGVuTH_baRG2xksCFEJqNhJFJfSVZrCdwUtQPRwbmJnMjBAxZUJRaPN_-jJ9oZPXckUfEKDqw6uZ2Fsyufa9-tOeEZAy/s200/DSCN2608+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrDN_kzANRAIzVuiF6vGhVeN9xOnPLwyjadpgT0gweJ5Hi4Le4v4g8cxjXyNczVj3bqPb5iEv9AUEskLm95ExvAvrujT6OKOVcZHyCYAKx6ncoBMy2q6733qJ9bQVek70mOsUqEYAquQJP/s1600/DSCN2588+(Small).JPG"><img style="WIDTH: 88px; HEIGHT: 80px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524974911283183554" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrDN_kzANRAIzVuiF6vGhVeN9xOnPLwyjadpgT0gweJ5Hi4Le4v4g8cxjXyNczVj3bqPb5iEv9AUEskLm95ExvAvrujT6OKOVcZHyCYAKx6ncoBMy2q6733qJ9bQVek70mOsUqEYAquQJP/s200/DSCN2588+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsLXURq_oLdfA3C9Zwyq31qOpJ0QhMYckr40RyrOhN80ys9Y4Fkc4CJkc9CDPpITCdbkxtTeiSNRQ2vLHPWcFs0EMX7V6XBn7UYXWZu-ePNfhSlphiwAxOr_jRqbTzTuJuN2JzKw5pCG_B/s1600/DSCN2587+(Small).JPG"><img style="WIDTH: 114px; HEIGHT: 81px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524974829354864178" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsLXURq_oLdfA3C9Zwyq31qOpJ0QhMYckr40RyrOhN80ys9Y4Fkc4CJkc9CDPpITCdbkxtTeiSNRQ2vLHPWcFs0EMX7V6XBn7UYXWZu-ePNfhSlphiwAxOr_jRqbTzTuJuN2JzKw5pCG_B/s200/DSCN2587+(Small).JPG" /></a>
<br />I cut the inlet air hole and welded 2.5" pipe in an angle so the air will swivel and create more heat in the center. I kept the pipe 2" inside that will be the thickness of the refractory in the furnace. I found my welding magnets very usefull for holding the pipe in place. After getting all my welding gear ready the pipe was perfectly welded into place. Small tip, when placing the cylinder on the side 2 wood battens under it will prevent it from rolling aside when using the grinder on it.
<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRnJPSnb23sAaeBCy5O1Z7qQ1Kg2UHgGxrgP5iFTN1Ft-a36v9N3396pBG5Mr9AjQb9eGZ_emo53Cmp7U87G6kX2yVzqPq3b8yvsN2jdkkq_KfKUkQjxD0_D8gFqx5foeYWjLUo42MpIAL/s1600/DSCN2615+(Small).JPG"><img style="WIDTH: 100px; HEIGHT: 78px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524977779399147234" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRnJPSnb23sAaeBCy5O1Z7qQ1Kg2UHgGxrgP5iFTN1Ft-a36v9N3396pBG5Mr9AjQb9eGZ_emo53Cmp7U87G6kX2yVzqPq3b8yvsN2jdkkq_KfKUkQjxD0_D8gFqx5foeYWjLUo42MpIAL/s200/DSCN2615+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPuv_p6LqqVrdraCow1yzLxlYXNDvgaZxix8Y3ZDh9dIT8NMJm32RJ0MjkyWefH1y3iBh4qga7DTtSIK7VTFAQtkcBWOZbdn6IzXWJwD3QY-Mbve8f1v_VQxQQFhyGMtDv5ibbWpfqK4fp/s1600/DSCN2621+(Small).JPG"><img style="WIDTH: 106px; HEIGHT: 80px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524977952872252114" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPuv_p6LqqVrdraCow1yzLxlYXNDvgaZxix8Y3ZDh9dIT8NMJm32RJ0MjkyWefH1y3iBh4qga7DTtSIK7VTFAQtkcBWOZbdn6IzXWJwD3QY-Mbve8f1v_VQxQQFhyGMtDv5ibbWpfqK4fp/s200/DSCN2621+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0l_RDnQNB-NAbGTUBlXpDj3I4zLeH6e3Z_ceWTIe6HYQrOhMZ9TjN6bwFqwucyCCfV-Q5joV3bp3P3KWqU3bdxF3SWkmCroDg5veRaxoU-BXjeI3VzgXXOnqNehG78ZnWgDN2q5rIQMgE/s1600/DSCN2624+(Small).JPG"><img style="WIDTH: 108px; HEIGHT: 79px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524978773386478450" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0l_RDnQNB-NAbGTUBlXpDj3I4zLeH6e3Z_ceWTIe6HYQrOhMZ9TjN6bwFqwucyCCfV-Q5joV3bp3P3KWqU3bdxF3SWkmCroDg5veRaxoU-BXjeI3VzgXXOnqNehG78ZnWgDN2q5rIQMgE/s200/DSCN2624+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiULEDd73Q93PAUv1ZI3yaKP52mPkUhQswTdmRxyI7S7Q-QieMlEw3D_rivSfKUQ3JpAxkky55qxKeaLE3njHRy7sWSlBEw63c4Y9vCJbAvvNaRRaJ00erbc3frpLEpPm-jPy3bx-EVPSFH/s1600/DSCN2620+(Small).JPG"><img style="WIDTH: 102px; HEIGHT: 79px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524978099478190210" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiULEDd73Q93PAUv1ZI3yaKP52mPkUhQswTdmRxyI7S7Q-QieMlEw3D_rivSfKUQ3JpAxkky55qxKeaLE3njHRy7sWSlBEw63c4Y9vCJbAvvNaRRaJ00erbc3frpLEpPm-jPy3bx-EVPSFH/s200/DSCN2620+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPl2xo8RUVWMxYLtbo-5rcJk9O-f4i8SiprPPSOeU6LeOHUNhXdKgUC-jBYQHafemNXhwINb8St3BDlgYNhFXC0E7bDWHoUtxRUQIePbAfMtdrTaUh0zyG1AS3VPNtOCBNVc7qfXQf6aKH/s1600/DSCN2623+(Small).JPG"><img style="WIDTH: 88px; HEIGHT: 81px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524978404859906658" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPl2xo8RUVWMxYLtbo-5rcJk9O-f4i8SiprPPSOeU6LeOHUNhXdKgUC-jBYQHafemNXhwINb8St3BDlgYNhFXC0E7bDWHoUtxRUQIePbAfMtdrTaUh0zyG1AS3VPNtOCBNVc7qfXQf6aKH/s200/DSCN2623+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiK9dYdSXSyMovbBvBew9W3Adr1hwDJsmOSXTNfuc3NBWuw3j3qdLOsHLLWJC9D1c14iWA0kOrmxCuI2Fw8wo20IyUs6tc0ozIMCt69pIkTy9sj7bhXWJ8H668sHUKaJqOWvn_LGnuHwF5e/s1600/DSCN2627+(Small).JPG"><img style="WIDTH: 88px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524978884496281906" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiK9dYdSXSyMovbBvBew9W3Adr1hwDJsmOSXTNfuc3NBWuw3j3qdLOsHLLWJC9D1c14iWA0kOrmxCuI2Fw8wo20IyUs6tc0ozIMCt69pIkTy9sj7bhXWJ8H668sHUKaJqOWvn_LGnuHwF5e/s200/DSCN2627+(Small).JPG" /></a>
<br />Next thing I made was the hinge system for the furnace lid. I used 20x20mm box iron from scrap metal I kept for "rainy day". I used my drill press for accurate 10mm holes. The 2 box iron that I welded to the lid I made longer to act as stopper preventing the lid from falling back.
<br />Before welding I set the lid in the correct position using the blue mark as guide. After lid was in place I secured it with large welding magnets and welded the hinge into place. I am very happy with the result and the hinge is very strong and sturdy.
<br />After finishing with the hinge I cut the outlet hole on the top of the cylinder (lid).
<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJq1c5KkbGqt47-vdWYn1qjpaT-X67mOCRRxsd5fFwRfsYMxYnWajCrlYAtKPG-DjYmcTw3mObGomXvIDBZZHLwjye_w3K6pQjqpNpNgAiNCdzIMkmUKOhbuVjPF7G4G2RUE_OE8ZSN6DK/s1600/DSCN2630+(Small).JPG"><img style="WIDTH: 104px; HEIGHT: 79px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524982358588252994" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJq1c5KkbGqt47-vdWYn1qjpaT-X67mOCRRxsd5fFwRfsYMxYnWajCrlYAtKPG-DjYmcTw3mObGomXvIDBZZHLwjye_w3K6pQjqpNpNgAiNCdzIMkmUKOhbuVjPF7G4G2RUE_OE8ZSN6DK/s200/DSCN2630+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgH4rc4JX5e-_M4duvRslaWh6p76Y9CCoQ8EvX1vZeM4pffPmPX3Qj15FYns1yhGey2PIkaoh5U3pEFZqg1zy-1TeXJ1zYuvouGUQK9eWDIrQTIG5PxMG534rFaOT8Egxq02F3VIaqF8pwy/s1600/DSCN2633+(Small).JPG"><img style="WIDTH: 114px; HEIGHT: 79px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524982490456435554" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgH4rc4JX5e-_M4duvRslaWh6p76Y9CCoQ8EvX1vZeM4pffPmPX3Qj15FYns1yhGey2PIkaoh5U3pEFZqg1zy-1TeXJ1zYuvouGUQK9eWDIrQTIG5PxMG534rFaOT8Egxq02F3VIaqF8pwy/s200/DSCN2633+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgs-QVTOVIVLeUCCO4Liy7PXEYh8C9oQbdiaxXz-GDh5Rprlxfh_CPS8_ZHyYv5cLeqrwS56xn5FubFW-CC7EukB-0h6P_a1zu3stUXddAOPYdkf9ZiY-4vMxc0zBn56lBAep35IUNAqEon/s1600/DSCN2637+(Small).JPG"><img style="WIDTH: 107px; HEIGHT: 78px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524982568872164034" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgs-QVTOVIVLeUCCO4Liy7PXEYh8C9oQbdiaxXz-GDh5Rprlxfh_CPS8_ZHyYv5cLeqrwS56xn5FubFW-CC7EukB-0h6P_a1zu3stUXddAOPYdkf9ZiY-4vMxc0zBn56lBAep35IUNAqEon/s200/DSCN2637+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6eSu_gquBibYz3Ry51NeWRW-WrI4GTa9thImvnwNSmOUwQOAbFsLhkFUcfFpUhzS6E16-fOHViWX1PMPAVBBc5oav5EqeO4Uy4OwfzEqIbzaUiYnnEIwFxyVlj27891coLzK7MC_AJVm0/s1600/DSCN2639+(Small).JPG"><img style="WIDTH: 97px; HEIGHT: 76px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524982858039955538" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6eSu_gquBibYz3Ry51NeWRW-WrI4GTa9thImvnwNSmOUwQOAbFsLhkFUcfFpUhzS6E16-fOHViWX1PMPAVBBc5oav5EqeO4Uy4OwfzEqIbzaUiYnnEIwFxyVlj27891coLzK7MC_AJVm0/s200/DSCN2639+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvGGc8vJHh0IaGSTW7MtaOp0Io2zb5X7fVC1zkmd4DTC36xy7jXQ8fl0LODxIaYV9Jpkp1l1GTxoJcakPjNNzp72tyRMQiSoWkZN2OSwqCoZuuYp2Qzt7tsgB0t65F-nSAzJqKDvzSMe4g/s1600/DSCN2647+(Small).JPG"><img style="WIDTH: 92px; HEIGHT: 74px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524983133965180050" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvGGc8vJHh0IaGSTW7MtaOp0Io2zb5X7fVC1zkmd4DTC36xy7jXQ8fl0LODxIaYV9Jpkp1l1GTxoJcakPjNNzp72tyRMQiSoWkZN2OSwqCoZuuYp2Qzt7tsgB0t65F-nSAzJqKDvzSMe4g/s200/DSCN2647+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEie2RNottDv5__YdJsvpzdcyhrAsJl22Lp-KO64q6ZrwQ-8d0JS6K_xM-0s4KKNsq6SjZsqF64chVk6zkdKW5IO1GNZXhjNE2DW_dIiROxht1Hzncz06pvXQURHVS0ElNwshZc0JmPLuehJ/s1600/dscn2642+(Small).JPG"><img style="WIDTH: 83px; HEIGHT: 76px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524982952953873298" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEie2RNottDv5__YdJsvpzdcyhrAsJl22Lp-KO64q6ZrwQ-8d0JS6K_xM-0s4KKNsq6SjZsqF64chVk6zkdKW5IO1GNZXhjNE2DW_dIiROxht1Hzncz06pvXQURHVS0ElNwshZc0JmPLuehJ/s200/dscn2642+(Small).JPG" /></a>
<br />Sometimes the refractory shrink or move so in order to keep refractory in place I used metal screws all around the furnace body and lid part.
<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8-A7o_GjVn1MdG7S9IRs1N4rCM9yVaPLazbxxPyQkClSSLSP90SEsfQBpa6ag7pFxwsA0E2Fkken545IFTnvZnWn5YaOf14_DeIr2lvPP5U3bbEFgi_lNng-kSkRSw6jdFg1J41nkqv7E/s1600/DSCN2650+(Small).JPG"><img style="WIDTH: 92px; HEIGHT: 76px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525064671820981202" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8-A7o_GjVn1MdG7S9IRs1N4rCM9yVaPLazbxxPyQkClSSLSP90SEsfQBpa6ag7pFxwsA0E2Fkken545IFTnvZnWn5YaOf14_DeIr2lvPP5U3bbEFgi_lNng-kSkRSw6jdFg1J41nkqv7E/s200/DSCN2650+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnaOl6WoutU7wtitZSnTSIXo2JZ8bqma-FI-s5Ulfsc_KGfgew3nRcmq_QP80TXaDqsd48ApPEVtPgXAHtYguH_9bBoXTK64FKxMMiJz7mwwlXOMHPUsA6QsxemIt50Ojm7rfn77e1fIAi/s1600/DSCN2653+(Small).JPG"><img style="WIDTH: 86px; HEIGHT: 74px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525064756920588050" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnaOl6WoutU7wtitZSnTSIXo2JZ8bqma-FI-s5Ulfsc_KGfgew3nRcmq_QP80TXaDqsd48ApPEVtPgXAHtYguH_9bBoXTK64FKxMMiJz7mwwlXOMHPUsA6QsxemIt50Ojm7rfn77e1fIAi/s200/DSCN2653+(Small).JPG" /></a> <img style="WIDTH: 94px; HEIGHT: 73px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525066213697666818" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivshRwHecEdcRCYwVWjm__YA6S1FsAI4B4u4aIFlVyCK4LEQkdRgxRuaAYFonl5up9fkaxBsCC8X6jhH79grQmBDhAjJRWjPzPFHWa6cP6cANNVcEc3tcw7tGyWf1wWt3Se4DjKJpHCUpH/s200/DSCN2654+(Small).JPG" /> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4fPFOkA9-XyDIHz6YfJlVDwUWDttlY9ulj2BldK6ZV0C4VLbQQHk6t-XtFRq9Rq9gLNjI-8N1uN2eeP0cPTCq_KFRT5VM1BVOhAf_A59IGPxHuZiBbsixKaKZKgpG3Dz_DpDyCzp743CC/s1600/DSCN2662+(Small).JPG"><img style="WIDTH: 108px; HEIGHT: 72px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525065062363394242" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4fPFOkA9-XyDIHz6YfJlVDwUWDttlY9ulj2BldK6ZV0C4VLbQQHk6t-XtFRq9Rq9gLNjI-8N1uN2eeP0cPTCq_KFRT5VM1BVOhAf_A59IGPxHuZiBbsixKaKZKgpG3Dz_DpDyCzp743CC/s200/DSCN2662+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZFHSif0QxlmTQ4Nsb3r9lsrUynVfAVhDDCA9B-PxxfxsOxO0v_h_8Hw2_Z8ZHHoK8w1uR2qmv0ADz8TgXVcFgvySqTFANpb6zjU5CcRVjXu1-15V9ruSx4SrDDvARslKc_wdkk0QjXQ7Q/s1600/DSCN2661+(Small).JPG"><img style="WIDTH: 97px; HEIGHT: 72px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525064952329609362" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZFHSif0QxlmTQ4Nsb3r9lsrUynVfAVhDDCA9B-PxxfxsOxO0v_h_8Hw2_Z8ZHHoK8w1uR2qmv0ADz8TgXVcFgvySqTFANpb6zjU5CcRVjXu1-15V9ruSx4SrDDvARslKc_wdkk0QjXQ7Q/s200/DSCN2661+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNtHoWmhHGKKMVZf60DnVD0XH-aqYPpWor5BvQhoVgorkW52iamDh1DlReWgInohJSYk_skE-YwBJ6MA5KXKHxXamYXLhyphenhyphen2cneGKPyi3Co6NkcwfUJ2kBZEZLeUW0n5ZufgTgkMF-_E1gU/s1600/DSCN2676+(Small).JPG"><img style="WIDTH: 98px; HEIGHT: 74px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525076317343084290" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNtHoWmhHGKKMVZf60DnVD0XH-aqYPpWor5BvQhoVgorkW52iamDh1DlReWgInohJSYk_skE-YwBJ6MA5KXKHxXamYXLhyphenhyphen2cneGKPyi3Co6NkcwfUJ2kBZEZLeUW0n5ZufgTgkMF-_E1gU/s200/DSCN2676+(Small).JPG" /></a>
<br />At this stage the foundry is almost ready for the refractory stage. I used plastic can of paint with a bit of extra cardboard on top to form the inner furnace core leaving 2" space around for the refractory. For the lid I used cardboad pipe from empty gravy box to form the outlet lid hole.
<br />The refractory I used is ready made fire cement comes in big 25kg bags all that is needed is to add a bit of water. I started mixing it using very small amount of water until I got a sticky paste.
<br />
<br /><div>Too much water is bad for any refractory. On the net many home made refractorys are combined of Perlite (cruashed)+cement+silica sand and fireclay. Good refractory means good insulation, good insulation keeps the needed high temperture in the furnace. I started filling the furnace from the base ramming the refractory with timber block to get all the air bubbles out, then I placed the plastic core into position and filled it all the way up with refractory keeping 2" width and after that I filled the lid.
<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1IpWf67XV_XbOHnCIB94glKa0W-aDXVRtsfFnylKiEfURcu-qtkQ1IGX0SMJ4XbvQuZljCvLY0wT8udDI6NHOO2kZOfFnemSZf7T8sjS3wRoCqyqUKEIx0s9nfZU8Lo7kd85WCThfNfB6/s1600/DSCN2670+(Small).JPG"><img style="WIDTH: 111px; HEIGHT: 70px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525074149348920290" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1IpWf67XV_XbOHnCIB94glKa0W-aDXVRtsfFnylKiEfURcu-qtkQ1IGX0SMJ4XbvQuZljCvLY0wT8udDI6NHOO2kZOfFnemSZf7T8sjS3wRoCqyqUKEIx0s9nfZU8Lo7kd85WCThfNfB6/s200/DSCN2670+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6oe-DoO73QVqBrzj5rx2Sa0OpiU4ZQi9C7CUFW88CT-kIUf_54K9929ox4A0tbQNknEfbiEqPpRMgqz4D69-cbbIOkQFA-UdlY5eJ_I5zvJAEBC8wKP_uRu4NX-h0TooAeur6o7xWdCI2/s1600/DSCN2664+(Small).JPG"><img style="WIDTH: 117px; HEIGHT: 70px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525073778506906594" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6oe-DoO73QVqBrzj5rx2Sa0OpiU4ZQi9C7CUFW88CT-kIUf_54K9929ox4A0tbQNknEfbiEqPpRMgqz4D69-cbbIOkQFA-UdlY5eJ_I5zvJAEBC8wKP_uRu4NX-h0TooAeur6o7xWdCI2/s200/DSCN2664+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiL7OYvusDOVKXtOm99vjr54ZbODmsQwHGfpWOBg44fQqVqLMht9_eYxbpThPaz3P2XSqVV8A8EGjYnJeLNIF-q5SvsPW5_77Q4B5LvV6llsa7sJRpjgdjZSMau-ay33IAH6CFNiW-BrxjY/s1600/DSCN2668+(Small).JPG"><img style="WIDTH: 107px; HEIGHT: 70px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525073942277067442" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiL7OYvusDOVKXtOm99vjr54ZbODmsQwHGfpWOBg44fQqVqLMht9_eYxbpThPaz3P2XSqVV8A8EGjYnJeLNIF-q5SvsPW5_77Q4B5LvV6llsa7sJRpjgdjZSMau-ay33IAH6CFNiW-BrxjY/s200/DSCN2668+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgd7Y5_btvLpoBdSSSMBTxWR6-6NKJL7Jfe4iD8NFSh__kktrHGjnN_O9sbi8NbHtoVHETsjNF899LPa5Sc8zXs0ZGIe57ucgqvt-pIy9OiODG1BlO3iEk6RZ5pQaHneHyqr3GVAHiojHBr/s1600/DSCN2674+(Small).JPG"><img style="WIDTH: 89px; HEIGHT: 67px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525075347747728594" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgd7Y5_btvLpoBdSSSMBTxWR6-6NKJL7Jfe4iD8NFSh__kktrHGjnN_O9sbi8NbHtoVHETsjNF899LPa5Sc8zXs0ZGIe57ucgqvt-pIy9OiODG1BlO3iEk6RZ5pQaHneHyqr3GVAHiojHBr/s200/DSCN2674+(Small).JPG" /></a> <img style="WIDTH: 86px; HEIGHT: 69px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525075182997925266" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgz39tOZiglOjyDja1vvrdZF7eIIrjxex_B07rwRSNveHmRPWcRg1FwYDyWzO9wJb9nDBYcsKmq7x_KWzjqAzDIRMJmN3OUjmkFWMb-8InSMdpoMQBAo2eUjgf7Zd8mLt-MGMLLBHolvCWV/s200/DSCN2671+(Small).JPG" /> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhviqQrScJwMx3Z6R5xQ-PGXDasFwY6rGf46OG73Z5uSi5L26HZ4duLpavLBe76Gvx-vx32ErTF6gG9pLJfBOPaXlImbH1vdn_gUxsIcCBvlMn_wMVR-m3crIlPOi6Ql7ctQW4KV9RN7938/s1600/DSCN2677+(Small).JPG"><img style="WIDTH: 96px; HEIGHT: 71px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525074691011205202" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhviqQrScJwMx3Z6R5xQ-PGXDasFwY6rGf46OG73Z5uSi5L26HZ4duLpavLBe76Gvx-vx32ErTF6gG9pLJfBOPaXlImbH1vdn_gUxsIcCBvlMn_wMVR-m3crIlPOi6Ql7ctQW4KV9RN7938/s200/DSCN2677+(Small).JPG" /></a>
<br />Every type of refractory have its own curing time and manufacture guidelines. If refractory is not cured properly it might crack under high temperature. The type of refractory I used had to be cured by lighting the foundry for a few hours keeping the temperature at 100°C this type of refractory is good for up to 1200°C (cured). After refractory was cured I lit the foundry first time with charcoal and after one hour when the temperature was over 1000°C I placed my hand on the outerside of the furnace and it just felt worm. So that was a good sign that the refractory doing its insulating part by keeping the heat inside the furnace.
<br />After the furance body was cured I welded handle for the furnace lid and welded 4 support washers to hold the refractory in the lid.
<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSYZs7jv8hmuWtxMPJZ1KxtbOGio_g0O23XoasmVoYdYhBBP3fzysaKWGv3lsZCEM8Tb4OS6Kg-4L4w5VtmtztmZFR7CFNcqtpl-f-w88i2cim_6tyATMsiuvSqbJW7eWsbTloX4Vx8akY/s1600/DSCN2691+(Small).JPG"><img style="WIDTH: 104px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525385306879108626" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSYZs7jv8hmuWtxMPJZ1KxtbOGio_g0O23XoasmVoYdYhBBP3fzysaKWGv3lsZCEM8Tb4OS6Kg-4L4w5VtmtztmZFR7CFNcqtpl-f-w88i2cim_6tyATMsiuvSqbJW7eWsbTloX4Vx8akY/s200/DSCN2691+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJvGnZtxdf5In5oGf1iwb6YvOWLZlqF0MPtCNVrIKb6_HyukcOAJZHAne_oBTVw3Gi66Tttgd4YKiKLFFHiYDZ2eq7mH7_KpcI_dlak68ju5domQvFF5REU3NmAzXOyqTdXo2bX8DiXrXk/s1600/DSCN2707+(Small).JPG"><img style="WIDTH: 114px; HEIGHT: 83px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525385811768413810" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJvGnZtxdf5In5oGf1iwb6YvOWLZlqF0MPtCNVrIKb6_HyukcOAJZHAne_oBTVw3Gi66Tttgd4YKiKLFFHiYDZ2eq7mH7_KpcI_dlak68ju5domQvFF5REU3NmAzXOyqTdXo2bX8DiXrXk/s200/DSCN2707+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiOoI1aQUZ-A8uR4YDNxxFVPkIxLQq3RQI5vHf-yqG-RBvrgbdA0xKe3RSnZ_CeCFVrEjJtGICzEbWYzQV-WoNcv2zUYq-UFSZY6cmgE9LdR1uKXxIIoJAkq6UQIvdGK25YulkgiDooVIv/s1600/DSCN2879+(Small).JPG"><img style="WIDTH: 106px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525387891488170850" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiOoI1aQUZ-A8uR4YDNxxFVPkIxLQq3RQI5vHf-yqG-RBvrgbdA0xKe3RSnZ_CeCFVrEjJtGICzEbWYzQV-WoNcv2zUYq-UFSZY6cmgE9LdR1uKXxIIoJAkq6UQIvdGK25YulkgiDooVIv/s200/DSCN2879+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaNVSCtYtHLk859cHwhm7x7pQkNh8GP-JziMRlro8cAAO91IOX7XY1zDF0uBn1nyqt44T2vxEXzD2q4vdopYt-0SxTZGIJ-eq_uXkXbn9VnHHaE_YBSz0bVg0hT89IX1-Uxm0Bj6p2-Rcx/s1600/DSCN2884+(Small).JPG"><img style="WIDTH: 108px; HEIGHT: 82px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525388061524769186" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaNVSCtYtHLk859cHwhm7x7pQkNh8GP-JziMRlro8cAAO91IOX7XY1zDF0uBn1nyqt44T2vxEXzD2q4vdopYt-0SxTZGIJ-eq_uXkXbn9VnHHaE_YBSz0bVg0hT89IX1-Uxm0Bj6p2-Rcx/s200/DSCN2884+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjq4MR7rlFfxcillKzTaBYwfE_aSceBznTi76VbZs9WdmFoI_-A8ZBoIetruAr3culLWN3GkqOKCf4O46DqE1xh7LRz3BiC-hWszeJsIStNsnlmUjvZNelcIpbwgqI5IjzYFsZmu-VI8aLk/s1600/DSCN2887+(Small).JPG"><img style="WIDTH: 90px; HEIGHT: 81px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525388195522717106" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjq4MR7rlFfxcillKzTaBYwfE_aSceBznTi76VbZs9WdmFoI_-A8ZBoIetruAr3culLWN3GkqOKCf4O46DqE1xh7LRz3BiC-hWszeJsIStNsnlmUjvZNelcIpbwgqI5IjzYFsZmu-VI8aLk/s200/DSCN2887+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIOlFNDfiSrmCjQHPxfPURqW3B_88zvby7SHf-DAPHZfK0kMAjNxyqZte-8CEQyganvjahxxuzBPInSHYjTGQNS-Cc8skklWYID-jymp9Cnqq_mvVQ5d2scMexsDlp7T4Yk0mgflX6U_wx/s1600/DSCN2886+(Small).JPG"><img style="WIDTH: 92px; HEIGHT: 81px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525388125686765378" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIOlFNDfiSrmCjQHPxfPURqW3B_88zvby7SHf-DAPHZfK0kMAjNxyqZte-8CEQyganvjahxxuzBPInSHYjTGQNS-Cc8skklWYID-jymp9Cnqq_mvVQ5d2scMexsDlp7T4Yk0mgflX6U_wx/s200/DSCN2886+(Small).JPG" /></a>
<br />The foundry was ready for action at this stage but I found moving it quite a task with all that heavy refractory. So I welded handles from 5mm rebars I took from my first furnace broken lid.
<br />After that I welded a small trolley for the furnace made out of scrap metal and hand trolley with 2 good wheels I found in a rubbish skip.
<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggNWGNzpjby9W1fEIqMinhvdOzfQG-RHM1pXFtQ0Xbi7IkMsCxhqQrJDEOgIH78cAExpXl_Ic1ApFKLMrD0g18GajdnjZwpPSXMk9RL8xVP_l43GuY4vtEMTZBXEWeogQM5TGUhUosVTPl/s1600/DSCN2989+(Small).JPG"><img style="WIDTH: 105px; HEIGHT: 77px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525391731099623490" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggNWGNzpjby9W1fEIqMinhvdOzfQG-RHM1pXFtQ0Xbi7IkMsCxhqQrJDEOgIH78cAExpXl_Ic1ApFKLMrD0g18GajdnjZwpPSXMk9RL8xVP_l43GuY4vtEMTZBXEWeogQM5TGUhUosVTPl/s200/DSCN2989+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilWogA5XqZdFxZ-0w3H6q1u9LMCOKxmIua4QYrDDbdcG0eZgOahwLghM2FVRgtDfK3_G0hNeX5vS5MYhQq7vsCHXHbnCxEkVGyT6rYaNePHY4fymxbaGKR90S1K6-oF8DCL526YG6-4IDU/s1600/DSCN2889+(Small).JPG"><img style="WIDTH: 103px; HEIGHT: 78px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525390486408682994" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilWogA5XqZdFxZ-0w3H6q1u9LMCOKxmIua4QYrDDbdcG0eZgOahwLghM2FVRgtDfK3_G0hNeX5vS5MYhQq7vsCHXHbnCxEkVGyT6rYaNePHY4fymxbaGKR90S1K6-oF8DCL526YG6-4IDU/s200/DSCN2889+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBc3NzddgO0W7ST996LisWtvfEKzC4tKbT4fH3I6tXUvWM9HIugIODRqUzsRtCNCGk_b4ccj-E6vX94VT8ozSSL-X3sJz-vCCMVnqfBigSk6vulefoZyRRvoIGJKOuTHFQPFh0H4wySUyg/s1600/DSCN2902+(Small).JPG"><img style="WIDTH: 121px; HEIGHT: 79px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525390704466830082" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBc3NzddgO0W7ST996LisWtvfEKzC4tKbT4fH3I6tXUvWM9HIugIODRqUzsRtCNCGk_b4ccj-E6vX94VT8ozSSL-X3sJz-vCCMVnqfBigSk6vulefoZyRRvoIGJKOuTHFQPFh0H4wySUyg/s200/DSCN2902+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1ZJ1AJ7bC71_UwDD93j1MuZcPwY_D1_B0KY-aUTnk_cECkBKZDm6kpxWwQG9g453PP3ZVvhJHDLO6pbJETVOXH-ZjxHb95yu_my9tg2lVY6kEeXjM8SjmaCuWI7-U6edybg6IgnFpva8E/s1600/DSCN2911+(Small).JPG"><img style="WIDTH: 113px; HEIGHT: 81px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525391045823064946" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1ZJ1AJ7bC71_UwDD93j1MuZcPwY_D1_B0KY-aUTnk_cECkBKZDm6kpxWwQG9g453PP3ZVvhJHDLO6pbJETVOXH-ZjxHb95yu_my9tg2lVY6kEeXjM8SjmaCuWI7-U6edybg6IgnFpva8E/s200/DSCN2911+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCVXbQrFOiuIVjwm83wLq2ChFm1l59vb2HDo8cxYCWAVS0j6_yBmUq_aE3uAUtglFfzRMYH8bfDOLX4zjc5sxSAPlPcftfB_9FLT8Vt9jAInZh4r3T8qi8ZQ4ga9Hj6O6QKbLXMkyegl3E/s1600/DSCN2917+(Small).JPG"><img style="WIDTH: 97px; HEIGHT: 80px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525391199583180898" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCVXbQrFOiuIVjwm83wLq2ChFm1l59vb2HDo8cxYCWAVS0j6_yBmUq_aE3uAUtglFfzRMYH8bfDOLX4zjc5sxSAPlPcftfB_9FLT8Vt9jAInZh4r3T8qi8ZQ4ga9Hj6O6QKbLXMkyegl3E/s200/DSCN2917+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4j5he6IL5u0Ibk7v4vRrdYkOfCtpH1Z4EoFEaNVioxnNOMqO9qrCE28nZ264wvIAag1qHgb6t8eGnRvKpuMhrifymyxKl7e6Kx9CN_mtZH9OcnirO95zmaqmWLTm12tSFuS0lTweFOMBW/s1600/DSCN2923+(Small).JPG"><img style="WIDTH: 95px; HEIGHT: 81px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525391610472477906" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4j5he6IL5u0Ibk7v4vRrdYkOfCtpH1Z4EoFEaNVioxnNOMqO9qrCE28nZ264wvIAag1qHgb6t8eGnRvKpuMhrifymyxKl7e6Kx9CN_mtZH9OcnirO95zmaqmWLTm12tSFuS0lTweFOMBW/s200/DSCN2923+(Small).JPG" /></a>
<br />Now its time for some melting, My furnace is HUNGRY time to feed it with some aluminum. I collected some aluminum from my house, some unused items. I made some tools for my old furnace and they are still good for this one. To get rid of the dross I used big spoon with holes.
<br />Cheaking the temp with multimiter at some stage showed over 1000°C.
<br />I used characoals and hair dryer connected to a hoover pipe as a air blower and pot as crucible.
<br />My first melt was parts of aluminum ladder, I used my muffin tray to cast the aluminum ingot.
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<br /><div><span style="color:#ff0000;"><strong><em><u>July 2011</u></em></strong> </span></div>Small upgrade. I found the lid hinges too long getting in my way a few times so I decided to make them a bit shorter using my angle grinder and welding a metal L angle.
<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0a2a7PyGq3xMfxY-7gsQA2ARbPno07IQD5HAXjoSzLG3p8r-bCNp-maPNJWqd3SzOlhHxlMW9IlQKLJqEnDxlxWycllq5m_vCurxw_PGu3K9BplT1gOT2rlxUcFFfocKhE8jlMSxfrhtJ/s1600/foundryIIupgrade2.JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5627088581681688178" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0a2a7PyGq3xMfxY-7gsQA2ARbPno07IQD5HAXjoSzLG3p8r-bCNp-maPNJWqd3SzOlhHxlMW9IlQKLJqEnDxlxWycllq5m_vCurxw_PGu3K9BplT1gOT2rlxUcFFfocKhE8jlMSxfrhtJ/s200/foundryIIupgrade2.JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWUfIgFsOpoSRyfdQ4KjdIYoPs_roVn9rgiqN216wbdpWsYLh1CQIlZJRdVKK2ydJFWtE8XFOPFCjOqoMAWeGM8r3T0h2iBpUYGzHgDTMx2_emSgTs6z75xu0AX2seoCrMQxeGJKfRaxdT/s1600/foundryIIupgarde1.JPG"><img style="WIDTH: 198px; HEIGHT: 143px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5627088575833999042" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWUfIgFsOpoSRyfdQ4KjdIYoPs_roVn9rgiqN216wbdpWsYLh1CQIlZJRdVKK2ydJFWtE8XFOPFCjOqoMAWeGM8r3T0h2iBpUYGzHgDTMx2_emSgTs6z75xu0AX2seoCrMQxeGJKfRaxdT/s200/foundryIIupgarde1.JPG" /></a>
<br />FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.comtag:blogger.com,1999:blog-5434634429369908904.post-27785633090086498252010-10-06T03:33:00.000-07:002011-01-24T01:40:00.402-08:00My first Mini (disposable) Charcoal foundry.This is the first disposable charcoal furnace that I built its purpose melting small amounts of aluminium into ingots or sand castings for small objects. I don't predict a long "shelf life" for my furnace before it will start cracking but I will get a few melts before I scrap it, This is just a prototype and in the future I will make a bigger and better furnace.<br />A few details about my furnace: I made it all 2" thick around including the furnace lid. I used Plywood, MDF, cardboard, chipboard all left overs from other jobs to make the furnace form.<br />The furnace tools I made from a 5mm construction rebar, can of beans and old bathrooms hooks.<br /><div><div><div><div><div><div><div><div><div><div><div><div><div><div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgs8oODZhqBYO7y90XGh-8_rsx5Zcr8UC1BAYFA0n2ytOTG0vmJhSxQVCzN2InDakxfQVt0Vvjo9xYUXM9QSs_YVqBfp1Ze8bmk-s1zQQe7RF6anVTbxlVObXkFi7l7WrKC5xJYWxGAh_SW/s1600/DSCN1098+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524881814086491170" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgs8oODZhqBYO7y90XGh-8_rsx5Zcr8UC1BAYFA0n2ytOTG0vmJhSxQVCzN2InDakxfQVt0Vvjo9xYUXM9QSs_YVqBfp1Ze8bmk-s1zQQe7RF6anVTbxlVObXkFi7l7WrKC5xJYWxGAh_SW/s200/DSCN1098+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6yLh6q8lCeDHLzooQy4bzahKNzPuHfRrfEu5vJzWqZLABrpS174hd5tVdsDYDzkiH7sf5g-HYTdt-JnNqqT92nPoAi_rEEnMm96q3osRqSMTj1t9IBNjj7daSG8n_OT_z-JpKqLH57ofM/s1600/DSCN1118+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524882259479450354" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6yLh6q8lCeDHLzooQy4bzahKNzPuHfRrfEu5vJzWqZLABrpS174hd5tVdsDYDzkiH7sf5g-HYTdt-JnNqqT92nPoAi_rEEnMm96q3osRqSMTj1t9IBNjj7daSG8n_OT_z-JpKqLH57ofM/s200/DSCN1118+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEOgEWdKoTW0Khib3q8DgxWC1UhcuT7cTSa5bbzWtl_0QrjVq3YqpTiOw557z8dPF_h_cVhIX-uVVELtJxIguZDTSabdQRNSwsGpjhMTz32djhL9aAt6XVbklo7MqXDyi1q0gXaqcG7S3D/s1600/DSCN1134+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524882635576263842" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEOgEWdKoTW0Khib3q8DgxWC1UhcuT7cTSa5bbzWtl_0QrjVq3YqpTiOw557z8dPF_h_cVhIX-uVVELtJxIguZDTSabdQRNSwsGpjhMTz32djhL9aAt6XVbklo7MqXDyi1q0gXaqcG7S3D/s200/DSCN1134+(Small).JPG" /></a> </div><div>To shape the furnace core I used an empty plastic can of paint. Cut it to the desired diamater leaving space for the charcoal / crucible and at least 2" to fill the refractory for furnace walls. Using masking tape to hold the can diamater shape makes it quick and easy to remove after your refractory is dry. Make a hole for the cardboard pipe or just tape the pipe to the can to prevent blockage of the opening. I used 10mm MDF cut to fit the plastic can diamater. It is important to cut the MDF into half this will help to take it off in later stages without breaking the fresh refractory. Make another 2 circles and screw them all together. Use the left over materials from your cuttings and attach them together. Use any flat scrap for the base. Place the cardboard pipe in the centre of the lid for the vent opening.<br />Strips of 5mm MDF will do for holding the rebars in place and will be very easy to snap off in the stripping stage. Screw the MDF into place, mark the hole positions and drill the holes.<br />I bent 5mm rebars to serve as handles for the lid. Place the handles in the holes and leave a 20mm gap from the base.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjU4E44PJoTfs1rvXWisFdsG06uNbYFcQ4X4PpGkNP6eBqc6iEX90Zbhl7YNF7zoRPflVwWZJM0UYJ_KkGZkRmWLAtvInHsB_Nq7OrkCsT37dGMkzqaABMDDkMrO44LfpENoKHML54gC5ws/s1600/DSCN1140+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524883515528025890" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjU4E44PJoTfs1rvXWisFdsG06uNbYFcQ4X4PpGkNP6eBqc6iEX90Zbhl7YNF7zoRPflVwWZJM0UYJ_KkGZkRmWLAtvInHsB_Nq7OrkCsT37dGMkzqaABMDDkMrO44LfpENoKHML54gC5ws/s200/DSCN1140+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_U43dXyr_tDNZ-SCRVw2cMcUOepDMyrlVSP2NNbWxVrepDfigrngSlNbTSlFjb14BROqNzRyi092rljYw0v95eMbREfQbrk7max4EW9sQKTj0gH5Fl6igOCOHEYiHqGPwglriTeMNCDNs/s1600/DSCN1141+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524883617163122450" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_U43dXyr_tDNZ-SCRVw2cMcUOepDMyrlVSP2NNbWxVrepDfigrngSlNbTSlFjb14BROqNzRyi092rljYw0v95eMbREfQbrk7max4EW9sQKTj0gH5Fl6igOCOHEYiHqGPwglriTeMNCDNs/s200/DSCN1141+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiMwSGOcpHJjv-AvR_6xEjHO0imcN6yD1JAculzqqEpRIA-qZ9uLGrtyRM9gM3C2rsaOJPZMgljdHSwNV-8gOKj81lQSdiYU4hAMyyYwWzF81wLW-Gop-tjscGQ17fBJA9iMmkDvfzTn6B/s1600/DSCN1152+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524883764665732770" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiMwSGOcpHJjv-AvR_6xEjHO0imcN6yD1JAculzqqEpRIA-qZ9uLGrtyRM9gM3C2rsaOJPZMgljdHSwNV-8gOKj81lQSdiYU4hAMyyYwWzF81wLW-Gop-tjscGQ17fBJA9iMmkDvfzTn6B/s200/DSCN1152+(Small).JPG" /></a><br />Refractory: The mix of materials chemically and physically will help hold furnaces high temperature avoiding thermal shock (in plain english, cracking).<br />In the image you can see 2 bits of ply attached to the inside walls of the furnace, they will be stripped of later and the gap left in the material will be a good handle grip for lifting the furnace.<br />Start from the base of the furnace and drill the copper pipe to the base center point, after that using a block of timber etc. compact the refractory and remove of all unwanted air bubbles.<br />Drill the center screw out and leave the copper pipe in its place. Attach the plastic can with the same screw in the center over the refractory.<br />Cover all sides around the plastic can with the refractory mix and compact as you go.<br />When you get near the top place the cover and secure it with timber to the furnace plywood walls.<br />When all is compacted well and covered use a hammer to tap on the plywood sides to get rid of any remaining air bubbles.<br />The refractory I used for this furnace was just cement+sand+fireclay and a small amount of water just turning it into a nice paste. When mixing all materials use gloves and respirator.</div></div></div></div></div></div><div>I knew It will probably crack at some stage but I got a few nice meltings before that. </div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiUG4fSWMfHJ7_KYs5TSVpe0U4Ee2PNl5ubJzmPQP05nryLVlbsaP3ol7TfCflt_WaKAMklLkVliM9Qo_dLPDSpZHxHDPcvHU62TXDaoIweuq-V3gfgkdn5jX3E7Oe-9ZOBM8EQ5_Pj4v-/s1600/DSCN1163+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524887548452985202" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiUG4fSWMfHJ7_KYs5TSVpe0U4Ee2PNl5ubJzmPQP05nryLVlbsaP3ol7TfCflt_WaKAMklLkVliM9Qo_dLPDSpZHxHDPcvHU62TXDaoIweuq-V3gfgkdn5jX3E7Oe-9ZOBM8EQ5_Pj4v-/s200/DSCN1163+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUjTAgXi2VX9W-sEiPG8ZIeg7b-0-jpdXa8886zgIddLRljdH08wxUsuFM6iTTplqXYF1HQv10I1Kdg0UlCSuFVQCbcRHm-zvxigrGUZC5GGIA_ojXhA0B2VsoYEqiJbxZ4XiSLAfXkBkf/s1600/DSCN1166+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524888692074515922" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUjTAgXi2VX9W-sEiPG8ZIeg7b-0-jpdXa8886zgIddLRljdH08wxUsuFM6iTTplqXYF1HQv10I1Kdg0UlCSuFVQCbcRHm-zvxigrGUZC5GGIA_ojXhA0B2VsoYEqiJbxZ4XiSLAfXkBkf/s200/DSCN1166+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoBLyFcTkHOPE24sRJRPXJPTlqXRtGBcMg2gpJCRXzMlAS6ZRns_XU1h01GMTlPMy_X1Ft5c-SydrRyDUujuMAdjFJ0wl6ffYI8pDmpnosgydsM-r2fjspfAWB6iq-1OugKKG9rYz3UzHM/s1600/DSCN1174+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524888826371535906" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoBLyFcTkHOPE24sRJRPXJPTlqXRtGBcMg2gpJCRXzMlAS6ZRns_XU1h01GMTlPMy_X1Ft5c-SydrRyDUujuMAdjFJ0wl6ffYI8pDmpnosgydsM-r2fjspfAWB6iq-1OugKKG9rYz3UzHM/s200/DSCN1174+(Small).JPG" /></a><br />It is a very important thing to remember: PATIENCE let the refractory dry don't be hasty to remove the cover or you will crack and break it, all your hard work will be for nothing.<br />Start taking the screws out and removing the sides of the furnace, you can use a chisel or such but don't wedge and pull it against the furnace.<br />The cardboard can be taken out with one finger, once it is wet it wont stick.<br />All the scrap you can throw away or use to make another furnace.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuoLHSk1L8diaPX8bCPvlqImGds6jdHG52gm7opk-hv7yY6_DWu9oP1ttoUdd460jndXy9zOv6hjoeKUrUZ8YAtFnxmRsYYqhZ8lNkYPsbzD7dk7rI7k3bhrQyxN9RzFFjcjrSokJfXc1i/s1600/DSCN1180+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524890137157700994" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuoLHSk1L8diaPX8bCPvlqImGds6jdHG52gm7opk-hv7yY6_DWu9oP1ttoUdd460jndXy9zOv6hjoeKUrUZ8YAtFnxmRsYYqhZ8lNkYPsbzD7dk7rI7k3bhrQyxN9RzFFjcjrSokJfXc1i/s200/DSCN1180+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFc1ffeDlRe50WJb8BA78D_uuDc6zTpiOV15uw88YZv3LUnTH8nh9ovC58SkhAYUyoUfLYgojE-yA8GU5JBOgb5zOPhGEpCkWc4Vt4dfhNHhtDFcJbZKTEtnPTCoXbopFRMFXw7pj1gVhR/s1600/DSCN1185+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524890430078473618" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFc1ffeDlRe50WJb8BA78D_uuDc6zTpiOV15uw88YZv3LUnTH8nh9ovC58SkhAYUyoUfLYgojE-yA8GU5JBOgb5zOPhGEpCkWc4Vt4dfhNHhtDFcJbZKTEtnPTCoXbopFRMFXw7pj1gVhR/s200/DSCN1185+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvw5BoY2M_HEfhdunslQnu1h7EUucIrhHm44IT4U7w-uGfFm4YcCgaSAmd7HFI5ipRskiRh7rgIDM0CV0ksHyuRK1iHdE8khNbP46bmqZMuq_4OYXCLhBis6_kiq1iNtIa8OlcFSGLaV4d/s1600/DSCN1240+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524890625293183954" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvw5BoY2M_HEfhdunslQnu1h7EUucIrhHm44IT4U7w-uGfFm4YcCgaSAmd7HFI5ipRskiRh7rgIDM0CV0ksHyuRK1iHdE8khNbP46bmqZMuq_4OYXCLhBis6_kiq1iNtIa8OlcFSGLaV4d/s200/DSCN1240+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOUMYHsHTE2xEHKfKvG43k44y-JiV6xb8977xAya_seoMEaiRgHb8ZrbeDyMKPAo37o81zVS6J2zISf5nFsOh0yG9WpZx1qOzhs_UsN3ztfjqw90quOam7EWD4NNboO1SP4as3T3DCj1eD/s1600/DSCN1267+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524890940510164434" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOUMYHsHTE2xEHKfKvG43k44y-JiV6xb8977xAya_seoMEaiRgHb8ZrbeDyMKPAo37o81zVS6J2zISf5nFsOh0yG9WpZx1qOzhs_UsN3ztfjqw90quOam7EWD4NNboO1SP4as3T3DCj1eD/s200/DSCN1267+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEil1lhU4JrRC9QrzBiuR7fiFik9hw9G5-nRX7LCOr0p4EE5h4ib8mHSQ1eWQYOMpeNHScglAzMaPH9NGx8W8Ntl91KJhSv5LIMCABnR6dObh_8FbMeoqbuu72gb9q9q-XtlhQ9xdDu0_MoT/s1600/DSCN1268+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524891167841241330" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEil1lhU4JrRC9QrzBiuR7fiFik9hw9G5-nRX7LCOr0p4EE5h4ib8mHSQ1eWQYOMpeNHScglAzMaPH9NGx8W8Ntl91KJhSv5LIMCABnR6dObh_8FbMeoqbuu72gb9q9q-XtlhQ9xdDu0_MoT/s200/DSCN1268+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXsR2-TYXIiqZ0SnPtBMNbfDJmEU1EAJLYaX2kZJUWNaACOBNETOus1kAwxEQvUgCRvlOWLNFecsCuqeJ0e4eCALg5n-DGKii2-EG4wgHu6DYoSzkl9MD0sGjUXIfvrGLLzY-mY6L7DFDY/s1600/DSCN1261+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524892992789341426" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXsR2-TYXIiqZ0SnPtBMNbfDJmEU1EAJLYaX2kZJUWNaACOBNETOus1kAwxEQvUgCRvlOWLNFecsCuqeJ0e4eCALg5n-DGKii2-EG4wgHu6DYoSzkl9MD0sGjUXIfvrGLLzY-mY6L7DFDY/s200/DSCN1261+(Small).JPG" /></a></div></div><div>Foundry crucible, The professional ones are made from different materials such as clay graphite, silicon carbide and more. They can be purchased from as little as a few bucks to couple of hundred.<br />The crucible I used is worth about 2$ - bargain..he..he.<br />I made the crucible from a used can of beans v shaping the lip for easy pouring, I drilled 2 holes to the sides of it and placed 2 bolts to act as lifting pins.<br />On the bottom I tied steel wire with a loop at the end.<br />The lifting fork and hook I made from 5mm construction rebar that I welded to an unused bathroom hook.<br />I also bought a 94c muffin tray (another bargain) to make some ingots.<br />The rebars are long enough to keep a safe distance from the boiling aluminium and your body. </div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0xC0kEg1q_QrWw-qOukPvOhSx6AgOS5poBu8vf9utngetiY0Tr4rJCCydsLZD9dH9PwEQzU4DJZJT2nMxDrazaYvZ-GfTQLhd5xhbBaXtamzy57RubSdqkEMLgP2iA8epVFZpnDcu82mc/s1600/DSCN1264+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524895176067022258" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0xC0kEg1q_QrWw-qOukPvOhSx6AgOS5poBu8vf9utngetiY0Tr4rJCCydsLZD9dH9PwEQzU4DJZJT2nMxDrazaYvZ-GfTQLhd5xhbBaXtamzy57RubSdqkEMLgP2iA8epVFZpnDcu82mc/s200/DSCN1264+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUXCUkUMhLso7-FtE3gwthDGR7qZBYe9FFQoMX00MEakutQ0zgQUua8DQmci3iYWx35zsQ1NOWmFZlg_wAMIoyuppYuUJBrCCb5gruKpLtXDP5FFET2bB52p7qojhyphenhyphenE9hKsgD6JRi7-JbF/s1600/DSCN3330+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524895707729362626" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUXCUkUMhLso7-FtE3gwthDGR7qZBYe9FFQoMX00MEakutQ0zgQUua8DQmci3iYWx35zsQ1NOWmFZlg_wAMIoyuppYuUJBrCCb5gruKpLtXDP5FFET2bB52p7qojhyphenhyphenE9hKsgD6JRi7-JbF/s200/DSCN3330+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEik8EVbFqwDq4daDH0t_vda4_J1naFUUItElStV5xcRUodUZQk6sF4MrL6JnwxqQthgIoKIxqVmzPfTVzohSO3uNm33e6NSGIepH8AiDBeLL8tlc-4ryjPrVAfRH67l218J-m1dwGu8r0cR/s1600/DSCN1463+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524896764670382354" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEik8EVbFqwDq4daDH0t_vda4_J1naFUUItElStV5xcRUodUZQk6sF4MrL6JnwxqQthgIoKIxqVmzPfTVzohSO3uNm33e6NSGIepH8AiDBeLL8tlc-4ryjPrVAfRH67l218J-m1dwGu8r0cR/s200/DSCN1463+(Small).JPG" /></a><br />We had great weather for a BBQ and a good opportunity to try my furnace. After lighting the BBQ coals I took a few and placed them on the base of the furnace and around the crucible. I used an old vacum cleaner pipe and taped my wifes hair dryer to one end after sneaking it out of the house. Later on she saw her hair dryer was attached to my furnace and lets just say I won't do it again. I placed the door handles and the locks without the nut cracker (no room in crucible) into the crucible coverd the top with the lid and turned the hair dryer on (low). I think after about 10 min I turned the dryer off, removed the vent block and looked into the lid vent hole and saw the aluminum handles were gone, for a moment I tought nothing melted but then I skimmed the scrap from the top and it looked like it was melting. I left it on for a few more minutes and I took off the lid used my DIY lifting tools and got all excited to see that liquid shiny as a mirror coming out into the muffin tray and forming into my first aluminium ingot.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvZxcm0YhrdsfiDd5oZIlxgOiOwqu9HoGLDkfeeg5ymuWhN0xApJl567v7YXsxv1Mhhbq0zc_G4dWCLBLDDsvSHxgDSd3D1h_3edd6xnRilqsSdQDwEO9yKVYqY27b7wA9XclM54JEHHgq/s1600/DSCN1545+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524899465013483698" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvZxcm0YhrdsfiDd5oZIlxgOiOwqu9HoGLDkfeeg5ymuWhN0xApJl567v7YXsxv1Mhhbq0zc_G4dWCLBLDDsvSHxgDSd3D1h_3edd6xnRilqsSdQDwEO9yKVYqY27b7wA9XclM54JEHHgq/s200/DSCN1545+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3f7zyVtJDH5EOrEGSTb5F-e7W-wgOjtMrvS8RqXz1CfXzD_VL8kR7dUJl1hSQwYlQ3PCbHs7d7yzMcz_1sU_H6szV02QMm0D5UMH-wVWlFt0DlYg3s5P0WTEEXfEGEQlFYQuDQIPuTz7D/s1600/DSCN3353+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524899942003833026" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3f7zyVtJDH5EOrEGSTb5F-e7W-wgOjtMrvS8RqXz1CfXzD_VL8kR7dUJl1hSQwYlQ3PCbHs7d7yzMcz_1sU_H6szV02QMm0D5UMH-wVWlFt0DlYg3s5P0WTEEXfEGEQlFYQuDQIPuTz7D/s200/DSCN3353+(Small).JPG" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2QwSUva1tmbUxC7cCL-l6a5OnkScpfpqtjnRaHTZ46v-Py-EEtSqcSiSFBWhOXWxGZes8fLLcT4em1qBVkKE772SNpoS6FYz4jEFHTKdB10gesIn8oQ3zxYnIkwKa76fnyp6PQ3yXSAxc/s1600/DSCN3352+(Small).JPG"><img style="WIDTH: 150px; HEIGHT: 200px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524900031721136754" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2QwSUva1tmbUxC7cCL-l6a5OnkScpfpqtjnRaHTZ46v-Py-EEtSqcSiSFBWhOXWxGZes8fLLcT4em1qBVkKE772SNpoS6FYz4jEFHTKdB10gesIn8oQ3zxYnIkwKa76fnyp6PQ3yXSAxc/s200/DSCN3352+(Small).JPG" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT502Xk461WnA57ZQah5U4bzkviho1su9L99GXYuAQRXvimsgalHL9SlWntVCDiVupHP-RwA2fWpm-okJ5UqBMNYqSFD65GmwHDh_XVwIn13Vtu90hb2gaSHWAqDmtPIYVddshsAlvjjyv/s1600/DSCN3363+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524899038780187794" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT502Xk461WnA57ZQah5U4bzkviho1su9L99GXYuAQRXvimsgalHL9SlWntVCDiVupHP-RwA2fWpm-okJ5UqBMNYqSFD65GmwHDh_XVwIn13Vtu90hb2gaSHWAqDmtPIYVddshsAlvjjyv/s200/DSCN3363+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOZHS2Y21nLAegEEPJt5X7QRquHpoF_0XlkNvxxv-0GhKOfwBDxGXf7mpfTO7GhpLW9hcZ9XE5ojIoUHkpKeqSRQEGnjSR1JdDSmUA1RjhPp3M_V8iMoriUxpt2NIAhFDlY4Gxlnz32aE8/s1600/DSCN3389+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524900687417812242" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOZHS2Y21nLAegEEPJt5X7QRquHpoF_0XlkNvxxv-0GhKOfwBDxGXf7mpfTO7GhpLW9hcZ9XE5ojIoUHkpKeqSRQEGnjSR1JdDSmUA1RjhPp3M_V8iMoriUxpt2NIAhFDlY4Gxlnz32aE8/s200/DSCN3389+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbzR_yL6a-6a1_YgMi3nfk6Phzzx9iDGYG-j7YXygannfT4B6G7u9TL_Ub5ZjNeGQcfeHqGIzDc11h5K6GpSFij5aV-2Yw1tC4npqVCUqRCSDy89jQtzuT1ktCBUhJjzkBy2IdwIIhztqq/s1600/DSCN3369+(Small).JPG"><img style="WIDTH: 150px; HEIGHT: 200px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524900276801085970" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbzR_yL6a-6a1_YgMi3nfk6Phzzx9iDGYG-j7YXygannfT4B6G7u9TL_Ub5ZjNeGQcfeHqGIzDc11h5K6GpSFij5aV-2Yw1tC4npqVCUqRCSDy89jQtzuT1ktCBUhJjzkBy2IdwIIhztqq/s200/DSCN3369+(Small).JPG" /></a></div><div><strong><u>This was a fun experiment !!! Now Some conclusions</u><br /></strong>As I predicted my furnace started to crack after more meltings. Before it will "die" I hope to get a small object sand casting. And after that I'll scrap this furnace and make a bigger and better one.<br />I don't recommend using tin cans <u>at all</u>, it can be dangerous, I got a few ingots out of it but one corn can I used broke inside the furnace with big holes.<br />Metal crucible should be made from thick steel, tin cans break very easily.<br />I also think refractory in a metal container such as empty gas cylinder will crack less.<br />This was a great experiment for first time aluminium melting.<br />This is a short video I made, I know its not great and my hand is in the way and a bit of dross fell into the muffin tray but it gives the general idea of ingot making.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj72SbCv2FKYQoLWPRMVWNRWRrjPFIz_Q4rVtmyghDjKogePPvR9_2gaKYQ0XGepQ_2fZONZpGf6jI-99WubUHvtI1H93xyKflEEQF1SlGJvYNsS1napYAtwKk5PzjtpdtEVrdwU0pBXX2V/s1600/DSCN2414+(Medium).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524903404645245778" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj72SbCv2FKYQoLWPRMVWNRWRrjPFIz_Q4rVtmyghDjKogePPvR9_2gaKYQ0XGepQ_2fZONZpGf6jI-99WubUHvtI1H93xyKflEEQF1SlGJvYNsS1napYAtwKk5PzjtpdtEVrdwU0pBXX2V/s200/DSCN2414+(Medium).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBXv52jyTHoEIktPdbvPDPOJhmtzwqmVbE2hP2Ro38jLKcCjchFa-6uTHCsbk2wsaTKmbready5nFBIEFB813Gzow7O4p1Na3m0Hi4w1fMLPIheECxrQ769kO-7tsBn_01nI9MqwGPrj0b/s1600/DSCN3395+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524903582796811490" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBXv52jyTHoEIktPdbvPDPOJhmtzwqmVbE2hP2Ro38jLKcCjchFa-6uTHCsbk2wsaTKmbready5nFBIEFB813Gzow7O4p1Na3m0Hi4w1fMLPIheECxrQ769kO-7tsBn_01nI9MqwGPrj0b/s200/DSCN3395+(Small).JPG" /></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6z1Q9WfuWMhxW4kTRlT30x717RlT5MzX0jYHXsu66obE2LrgP9KlO7GXRv1e-LRSR1N-POhNV5MB6q2Q187fsLXCyn0Uhs5lqQeMmUTj1sBKKAvK0mlxVp87FFnxPfFERCUhmGg_Aadz4/s1600/DSCN1554+(Small).JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5524903721650032690" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6z1Q9WfuWMhxW4kTRlT30x717RlT5MzX0jYHXsu66obE2LrgP9KlO7GXRv1e-LRSR1N-POhNV5MB6q2Q187fsLXCyn0Uhs5lqQeMmUTj1sBKKAvK0mlxVp87FFnxPfFERCUhmGg_Aadz4/s200/DSCN1554+(Small).JPG" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguZQ-JsPppaWmH1e1QX4oIKqV3fdwXRs-JQetkR86Dyd138X5KnY9TRjvuUal235Nr2TsHfiCQBfX1jJlYxKT46QHKhWekkUUn-H_ugMfX-JiTgG1zWFk6ku3AXe1dyDqzgv23QT6IdnyK/s1600/DSCN1528+(Small).JPG"><object width="425" height="344"><param name="movie" value="http://www.youtube.com/v/alqa6VSWHLk?fs=1&hl=en_US&color1=0x5d1719&color2=0xcd311b"><param name="allowFullScreen" value="true"><param name="allowscriptaccess" value="always"><embed src="http://www.youtube.com/v/alqa6VSWHLk?fs=1&hl=en_US&color1=0x5d1719&color2=0xcd311b" type="application/x-shockwave-flash" allowscriptaccess="always" allowfullscreen="true" width="380" height="280"></embed></object></a>__<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-fLFShW8Ep1BmXXflgRVw6hfnXuTKtRYxd37H3mA-909gcTNydLVd5NVN-8TKjl-BpB7j2FERnElv0EaU09Qf5AQhjGSAyG0AbE6cPjmDlOX3-JKb87n2STv4Y3bCk9vqBqEoORegdeKd/s1600/aluminumfurnace.JPG"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5525062675877222434" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-fLFShW8Ep1BmXXflgRVw6hfnXuTKtRYxd37H3mA-909gcTNydLVd5NVN-8TKjl-BpB7j2FERnElv0EaU09Qf5AQhjGSAyG0AbE6cPjmDlOX3-JKb87n2STv4Y3bCk9vqBqEoORegdeKd/s200/aluminumfurnace.JPG" /></a></div></div></div></div></div></div></div></div>FlamingFurnacehttp://www.blogger.com/profile/05711316858800111186noreply@blogger.com