Technical Tuck Goes Sand Casting!

Ryan, I posted up in Tuck's thread by mistake, it was meant for here.

 

Silent Rick:
i still don't get intake manifolds and valve covers, how do you create the voids?

A "core" is used to form interior voids. think of a pipe. the mold makes the outside and a round core is placed in the mold to form the negative space that will be the inside of the pipe. each end of the core registers on spots in the mold to keep it oriented. (remember "core shift" when checking your block for boring?) The molten metal flows around the interior core because its melting point is higher than the metal. Once the metal solidifies, the core sand is knocked out, leaving the interior. The interior can be as complicated as the core can be formed. "freeze plug" holes are actually where the water jacket cores are supported in the mold.

 

I made some tools last night just to make things smoother- but one of the tools I think works awesome is an apple corer- the kind you push through and then it has a plunger-
I use it to cut all my risers and then use the plunger to push the sand out. You can get them at the dollar store!

I need to get a steel bucket for dross, I knock it on my bricks too.

 

@Ryan can you move his post, it’s a good one-? He posted in my truck thread- (I tried too but couldn’t figure out how to get it here)

 

Thanks Moriarity.
Ryan, if you go to the HomeFoundry site and scroll down to "Links to useful information", there is a sticky for Foundry 101. Some of the shortcuts have been lost, but if you scroll down to Mach's Sep 14, 2021 post there is a good link.

 

Here are a couple to tools that I use to handle the crucibles. One to take the crucible out of the open top kiln and another to handle the pouring.

 

Interesting article about how 3D printing a mold saved a rare Delage. With todays tech, including using 3D scanning with an iPhone, and 3D printing, a whole new approach is at hand for the hobbyist.

https://www.abc.net.au/news/2017-03-27/saving-the-last-delage-type-s-grand-prix-car/8310958

 

I went through the process of building a muller, then a foundry furnace, and flasks, and patterns, and molding sundries, and then I discovered lost foam casting, and haven't made a green sand part since. Y T guru Kelley Cofield (sp.?) Shows how to do simple to very complex castings with few materials and tools, or stuff made with more high tech tools such as cnc routers. You make the exact part you want out of plastic foam, coat it with a slurry of drywall cement and water,let it dry, bury it in plain dry sand (vibrating the container while adding the sand) , pour the aluminum into the foam pattern, and like magic the aluminum takes the place of the foam, and you have your part! I've cast many finned aluminum parts including valve covers, air cleaners, etc. With mostly great results.

 

pics!

 

Tuck is a ruler. Despite being in Kanada

 

I built a bucket / charcoal furnace years ago, got as far as making ingots, started a batch of green sand, and a temporary 2 x 4 flask, and then stalled. been thinking lots lately about dragging all that stuff back out and seeing if I can't get an actual part made

 

He's up here in Kanada?
I thought he was in Minnesota.

 

Hmm a finned alu valvecover for the Buick wouldnt look wrong.

 

It's an old HAMB joke.

 

I have this little race car mold. Any advice on poring aluminum in it and see what I get? Thanks, Gary

 

Neat. Looks like a tether car body.
What is the mold made from, cast iron or steel?
I made a permanent piston mold for my small engine out of cast iron and had excellent results by coating it with motor oil. I poured hot and got good results after the mold stabilized at about 500F.
I would start by pre heating with a torch to insure there is no moisture, spray a little oil on it and then give it a try. It would be good to know the volume so it isn't poured short. It looks like it has plenty of vents.

 

I believe it is steel Thanks for the info, Gary

 

Hahaha. I bought some dies from Tuck in the past. He had them listed on eBay. He had or make offer listed. So I made an offer and I was waiting to hear back. And then I sent him another text and said, "I figured out who you are, you are Tuck from the HAMB." He sent me back a reply that had his phone number and said, "Call me "
When I was talking to him on the phone, I felt all giddy inside like I was talking to a rock star.

Actually I was!!!

 

When I was building my roadster I went on the hunt for some 36 windscreen posts (unobtainium or very expensive at the time, no repros available), and saw a night school class for metal casting. I signed up, and learned the basics, making patterns, mixing sand, etc, , and we were asked to bring in something which we would like to cast as a project. I borrowed a pair and cast them, a couple in brass ( "gunmetal" actually) and a couple in cast iron. I felt a lot better chopping down some I made than a genuine set. At the time I was working for a uni, and they were throwing out all of their casting equipment (because it's all done "on line" now, and it's safer!!!!) so I grabbed copes, scoops, bentonite, all I could get my hands on. This was set up at my bro's place, he made a propane fuelled furnace using a 20 litre drum. We cast a bunch of club plaques, and other small bits. When you break open the steaming sand to reveal the prize. it's like opening a christmas present!

 

There is excellent info in this thread. Keep the information coming.

 

I've never done it, but I've been told that old aluminum wheels bust up & melt down for casting very well.

 

When casting perhaps “coolest” is not the most appropriate word to use...LOL