FallibleFlyer
Well-known member
Cast Aluminum Squares
I've been eyeballing some of nice cast welding squares out there. As it sits today, I'm still using the cheapo harbor freight magnetic squares (the little red arrows) and while nice, at times I just wish I could clamp it all together. The ones for sale out there that I liked, are just a bit too much money for me. Besides, its fun to make your own tools, right?
So, I modeled it up in CAD, 3D printed it, and today did the first ever casting of it. Okay, full discretion.. this is the second attempt. My first design ended up warping pretty terribly when it was cooling, so this one is more symmetrical.
Note, the grey piece shown is used to support the sand on the first side.
View media item 103690
View media item 103691
View media item 103693
It came out okay, there was some pretty bad breakout on the seam. I figure it would as I modeled up that edge with zero draft to reduce my adjustment later. There will be a few more cast before I get to the cleanup phase, so this will likely just be the scrap/test one.
What I'm looking for, is any advice on finishing this "square." I do not have a mill or know anyone that does so I'm stuck hand filing and sanding. A preliminary check shows that the casting at least hasn't warped and is pretty darn close to square, just need finishing. My plan is to cut off the excess and then file off the flashing without removing any more than necessary. Thinking I'm more likely to cause more harm than good by trying to get a uniform machined finish with a hand file. Thoughts?
I've been eyeballing some of nice cast welding squares out there. As it sits today, I'm still using the cheapo harbor freight magnetic squares (the little red arrows) and while nice, at times I just wish I could clamp it all together. The ones for sale out there that I liked, are just a bit too much money for me. Besides, its fun to make your own tools, right?
So, I modeled it up in CAD, 3D printed it, and today did the first ever casting of it. Okay, full discretion.. this is the second attempt. My first design ended up warping pretty terribly when it was cooling, so this one is more symmetrical.
Note, the grey piece shown is used to support the sand on the first side.
View media item 103690
View media item 103691
View media item 103693
It came out okay, there was some pretty bad breakout on the seam. I figure it would as I modeled up that edge with zero draft to reduce my adjustment later. There will be a few more cast before I get to the cleanup phase, so this will likely just be the scrap/test one.
What I'm looking for, is any advice on finishing this "square." I do not have a mill or know anyone that does so I'm stuck hand filing and sanding. A preliminary check shows that the casting at least hasn't warped and is pretty darn close to square, just need finishing. My plan is to cut off the excess and then file off the flashing without removing any more than necessary. Thinking I'm more likely to cause more harm than good by trying to get a uniform machined finish with a hand file. Thoughts?
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