Hot Rods Anyone know how to get something custom cast in aluminum?

I'm going to run two 4bbl carbs on the Hemi I'm having built for my '30 Model A coupe. The problem is trying to find intake scoops for the 4bbl carbs. All the stuff I like is for Stromberg carbs. I have yet to see anything I like for the 4bbl. My thought was to buy a couple of the Stromberg sized scoops that I like and modify or have them modified to 4bbl size somehow (cut and weld?). I really don't know how that would be best done. Then perhaps use the one that gets done as a pattern to cast some up. This isn't a business venture, maybe I'd just put a few out there for guys who would like some. Maybe not. Have you guys got any ideas on this? Again, I'm not trying to make money, I'm looking for info and advice on how to do it, where to do it, and what it might cost. I found some that I like, I will try to attach a photo to this post.

 

Alum casting, has a few tricks,one is after the alum flows iinto the mold/sandpattern> it cools to a smallere size=about 3/16in. to the foot. To have the finished casting be right size,the mold/pattern must start out bigger by that amount. Most foundry,don't went to play with small orders,of less then a few 100 or more min.
Some school shops have the things to do tiny things. But few also have core n pattern set up. You must make your own master pattern.{ called match plates } Look for a HAMB guy ,who has done something by his self.
On another note,look for anything with close to a shape n size,that not auto,,cut it and or weld,tell it is something you like;;;; Out door electrical hoods[are alum. and some are big like 4bbl,may be a starting point. Look around.

 

options, learn how to make a pattern and have castings made, see if there are any home hobbyist casters in your area who can help you, maybe a school or Tech that do a course on casting? last option pay someone to design and make patterns for you to take to a foundry and have cast ($$$$$$!) I dont think slicing and dicing would work on a scoop like that

 

I have made several molds and had a few parts cast in Aluminum. Not hard if you know yer chit

 

How would you do the inside opening ? Do you know anyone with a 3D printer

 

Bootlegged some nice typical size 11 MOON gas pedals in High School. When they came out of the sand, they were a size 9!
Smaller guys bought 'em up... (sophomores)

Ever build model planes? B*** wood would carve and belt sand easily, works well with tools... Just carve out the main profile, then 'gut' it.
You could also cut it in half, shape both, then glue the 'Master' ('plug') back together.
Larger than you need by 3/16"...Or, just fat casting at the base, then lightly grind the finished aluminum scoops. (been there, done this...wet sand, box mold)

 

I use Poplar for my patterns

 

Switch panel and gas pedal. The heel loop is a paint stick on the pattern!

 

The OP’s scoops would require an inner core. Not a job for the first timer.

 

totally true, but a LOT of us were first timers!

 

Here you go!

 

3d print with low melting temperature material. You've just made the modern equivalent of the lost wax casting process. Like mentioned above, you need to upsize for shrinkage, but the programming should be able to make those allowances.

Surely someone on here has done this before and can fill in the BIG gaps.

Hey, I'm an idea man! They call it an engineer. We get other people to figure out how to make a widget once we have the wet dream!

 

Mooneyes comes closest

 

Hmmm, I didn't find that Mooneyes piece when I searched - that might work. Thanks for that!

 

Good luck on your casting. Not sure if you came across these......still made......a take off of the 60's Cal Custom 40-40. US made.

 

Those are pretty interesting too. Any idea who sells them?

 

Arias makes it.....but looks like it's out of stock right now.
https://ariascomponents.com/product/surfer-air-scoop/
https://www.whiteowlspeed.com/product/arias-components-scoop-surfer/

 

Mandrel bent polished 14 gauge stainless steel tubing.

 

Hey Ricky - thats a promising idea. I never thought of that. I wonder how big I need and where to get it. Time to hit Google again!

 

I saw them, but as you said, Arias seems to be out of stock on most of their stuff.

 

Google search "ship cowl vents" and you will get lots of hits. They tend to come in bigger sizes like you are looking for. You will find new as well as old salvage.
They can look a bit awkward with odd-shaped scoops but if you keep up your search you will eventually spot something with possibilities. The "low profile" ones in particular may get your attention.

 

Plenty of air but they look like something you’d see in the back of a diesel 4x4.

 

Look into "printed sand" technology... It has something to do with 3D aluminum castings.....

 

I have two large mandrel bent 90 degree stainless elbows. They are either 3or 4 inch. I would have to look for them in my stash. $20 each plus shipping

 

carb neck is 5-1/8" dia

 

I appreciate wanting to do something different, but you might rethink and consider something a little more typical.

"Typical" hot rod is still way cooler than anything.
They're so purdy.
And they fit.
And they work.
And you'll have more time to cut and grind and drill and sand and polish something else.

 

You can have casting wax 3D printed. Then investment cast it and you won't need a core. You can also carve them out of foam and sand cast. Again, no core needed.
https://www.google.com/search?q=diy...#fpstate=ive&vld=cid:d274ad1a,vid:ynQ0g-y08bs

 

As others have pointed out the major cost of a small run of castings is the pattern making. In itself pattern making isn't difficult to do yourself, you just need to make the shape you need to get cast in metal from (usually) wood. The shape you make will need to 'draw' from the mold, i.e. no overhanging parts. If the casting needs an internal hollow section this is done by adding sand 'cores' formed in a corebox; you need to make the corebox as a negative of the internal shape you want. This is a (terrible quality) photo of the wooden pattern, the wooden corebox (shown in the two halves in which I made it) and the finished castings which came from it. Notice that the wooden pattern has 'core prints' added which locate the sand core(s). The foundryman rams the cores up with a special sand which sets like concrete when a puff of Co2 gas is injected, allowing each sand core to be placed into the core print impressions left in the sand mold.

TBH, I'm not sure that a relatively complex shaped cored casting is a good place to start if you don't have previous experience. But don't rule out casting as a solution, all of my 'interesting' cars have custom made castings on them, including bellhousings and the like.

 

I like this 4bbl scoop: https://www.obrientruckers.com/air-cleaner-oval-opening-4-bbl-scoop-short.html

I also believe the shrinkage factor for aluminum is 3% when cast but that would have to be verified.