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Above 1200 Sq/FT Cleaning Up My Shop

Wokspaces above 1200 squarefeet.
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oldironfarmer

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Thanks, Drives.

The rest of the story. Monty was taking off work after that day because his wife was in ICU recovering from cancer surgery and he was to have a week off to care for her. The community is pulling together to assist, of course.
 
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Craptain

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Apr 18, 2013
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Tampa Bay FL
Thanks, Drives.



The rest of the story. Monty was taking off work after that day because his wife was in ICU recovering from cancer surgery and he was to have a week off to care for her. The community is pulling together to assist, of course.
It's good to hear the community doing what is right in this day and age. Prayers and sympathy are all well and good, but real help is also needed.
Please tell us that he died at work and not as a result of his duties. I need to believe that L.E. officers are safe somewhere in this country.

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oldironfarmer

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It's good to hear the community doing what is right in this day and age. Prayers and sympathy are all well and good, but real help is also needed.
Please tell us that he died at work and not as a result of his duties. I need to believe that L.E. officers are safe somewhere in this country.

Sent from my SM-G930T using Tapatalk

What we've heard is that he was going to pick up a coworker to go to a training day, before dawn, and a car crossed the centerline and hit him head on. So your statement is hard to answer, he did die performing his duties but was not murdered because of his line of work.

But alas we are not immune to the craziness. Dwight Woodrell Jr. was 36 years old when he was murdered at 3:00 AM in 2001. He also was a friend and used to buy hay from me. A very fine young man.
 

86turbodsl

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So sorry to hear of your loss Andy. There is never enough time with family and friends. [emoji3525]

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Guster

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Mar 11, 2012
Messages
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Location
Auckland, New Zealand
My condolences to you for the loss of your friend Andy. Always sad when car accidents happen so indiscriminately.

Your cabinet shelves are coming along great and curious about your long reach clamp. The part you laid out with the cardboard templates reminds me of an airplane control surface component.
 

Craptain

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Yes you answered the question well. Automobile accidents happen everywhere and at any time. But at least he didn't die from the malicious actions of a criminal.

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carlquib

Member
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Mar 22, 2016
Messages
18
Sorry to hear about the loss of your friend. Here are the pictures I promised of the business end of my ball turning tool. I had no idea it was so hard to take a photo of small shiny things. I'm still not really satisfied with the pictures but it is the best I can do with what I've got. The tool with the bluing is trying to show the .020" land I use for harder materials. Without the blue you couldn't even tell the land was there. I really need to figure out how to put the pictures inline, so they can be accompanied and separated by text. 786da3e8894d2899270c222cdbd3b0e3.jpg041866cb84093920fff98bd2bb48ec85.jpgd272bec613951d65796efd7e9b5b814b.jpg

My name is Brian and I'm a toolaholic.
 

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oldironfarmer

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Really sorry for your loss Andy, as well as his family and friends.

Celebrate his life .

Thanks, Rian.

We will celebrate his life. They're having his funeral at the school event center to get more room.

So sorry to hear of your loss Andy. There is never enough time with family and friends. [emoji3525]

Sent from my LG-TP450 using Tapatalk

Thank you. Family and friends.

My condolences to you for the loss of your friend Andy. Always sad when car accidents happen so indiscriminately.

Your cabinet shelves are coming along great and curious about your long reach clamp. The part you laid out with the cardboard templates reminds me of an airplane control surface component.

Thanks, Eugene.

The clamp does look like a bell crank. It's just going to have a jack screw between the two short ends.

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Got it all glued up and sealed, then coated with mud, I may get to pour it tomorrow.

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Yes you answered the question well. Automobile accidents happen everywhere and at any time. But at least he didn't die from the malicious actions of a criminal.

Sent from my SM-G930T using Tapatalk

Yes, I'm glad he wasn't murdered.

Sorry to hear about the loss of your friend. Here are the pictures I promised of the business end of my ball turning tool. I had no idea it was so hard to take a photo of small shiny things. I'm still not really satisfied with the pictures but it is the best I can do with what I've got. The tool with the bluing is trying to show the .020" land I use for harder materials. Without the blue you couldn't even tell the land was there. I really need to figure out how to put the pictures inline, so they can be accompanied and separated by text. 786da3e8894d2899270c222cdbd3b0e3.jpg041866cb84093920fff98bd2bb48ec85.jpgd272bec613951d65796efd7e9b5b814b.jpg

My name is Brian and I'm a toolaholic.

Thanks for the condolences and for the great pictures. Those are tough pictures to take. You sure put a nice dish in the end of the tool.

Thanks again!

Andy I am truly sorry to read of the loss of your friend. Its never easy especially at work.

Our condolences

Thank you, Steve.

I worked on the shelf a bit today, and spent some time stowing aluminium ingots. It was fun stacking them up.

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That's the first bucket full.

Here's five buckets full.

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I have one bucket of cast ingots which i want to keep separate, and two buckets now of muffins. They'll get melted first.

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They take up a LOT less space stacked, less than I thought they would.

Thanks for stopping by.
 

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CraigRK

Active member
Joined
Apr 23, 2016
Messages
27
Maybe I'll get some shop time tomorrow. We've had a tough week. My friend who has the portable sawmill was killed at work. He was the Pawnee County Undersheriff, Monty Johnson. He will be sorely missed. He was a blacksmith buddy too. All around great guy.

Spend time with your family and friends. Never know when you won't come home from work.

Andy,

So sorry to hear this, my thoughts with his family and friends. I don't post often, but on here as often as I dare to keep up with your exploits.

All the best,
Craig
 

Bob Heine

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Oct 24, 2009
Messages
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Location
Boca Raton, Florida
Andy, I go through life pretty oblivious but every time I hear of a tragedy like Monty, I am reminded how fragile and fleeting life is. Nothing I can say makes it better but thank you for reminding me to call my kids, hug my wife and ask my invisible friend if she can stop letting this stuff happen. When you celebrate his life with the other mourners, know that I'm thinking of all of you.
 

Farmall450

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Joined
Dec 23, 2011
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Location
Marengo, Illinois
That's terrible news about your friend. Terrible way to die on the line of duty, ignorance of another driver. Terrible for anyone, really.

Sorry to hear that, Andy.
 
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oldironfarmer

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Location
Terlton, Oklahoma
Andy sorry to hear about your friend. I'm sure his loss is our loss also. Bobby

Thanks, Bobby. I hope Sarah is improving.

Andy,

So sorry to hear this, my thoughts with his family and friends. I don't post often, but on here as often as I dare to keep up with your exploits.

All the best,
Craig

Thanks, Craig. Thanks for stopping by.

Andy, I go through life pretty oblivious but every time I hear of a tragedy like Monty, I am reminded how fragile and fleeting life is. Nothing I can say makes it better but thank you for reminding me to call my kids, hug my wife and ask my invisible friend if she can stop letting this stuff happen. When you celebrate his life with the other mourners, know that I'm thinking of all of you.

This stuff is part of the world we live in. I'm reminded your accident could have been worse and we would not know about it.

That's terrible news about your friend. Terrible way to die on the line of duty, ignorance of another driver. Terrible for anyone, really.

Sorry to hear that, Andy.

Thanks. I guess we'll never know what really happened.

Thanks for the condolences, everyone.
 

qdod

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Jan 18, 2018
Messages
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I saw in some of the earlier photos and was wondering if you had any rear rims for a Farmall tractor. Size is 13.6-38??
 
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gman007

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West Michigan
Andy
I was catching up with your thread when I read about your loss. It is truly sad news as Monty seems to have been an all around great guy. RIP Monty Johnson!

I really like how you have stacked the Aluminum ingots. It seems your shop is now turning into the Fort Knox of Aluminum world :thumbup:

PS
And since your shop now is the Fort Knox of Aluminum, chances that you will score more high quality free drills such as Milwaukee etc, are even higher. You might even want to place an ad in the BurglarsRUs.com and invite such donations for a good cause. :lol_hitti
 
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KST1

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Jun 22, 2005
Messages
38
Location
Illinois
Sorry for your loss Andy. We learn a lot about living from you in this thread, and also about how to handle a tragic event like this. You mention celebrating Monty's life. Which is the point, rather than dwelling on the end. Thank you for another lesson.

-Derek
 
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oldironfarmer

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While catching up on your thread, I was saddened to read about the loss of your friend.

There's seldom a good way or good time to die, particularly for family and friends.

My condolences Andy.



Sent from my SM-G950F using The Garage Journal mobile app

Thank you Mark. A friend's father said "there's never a convenient time to die". I always thought that was an interesting perspective. We had a friend die of a heart attack when driving his welding truck home about twenty years ago. His swamper managed to get it pulled over safely. I spoke to his widow Sunday and confessed to her, that she was the first one I thought about. Her husband did not come home that day, she was a stay at home mom.

I saw in some of the earlier photos and was wondering if you had any rear rims for a Farmall tractor. Size is 13.6-38??

13.6-38 is a tire size. I do have some 12" 38" rims, but they are generic, you can buy the base rim about anywhere. They only fit H's and M's. What tractor do you have?

I'm sorry to hear about your friend.

Thanks, my friend.

Andy
I was catching up with your thread when I read about your loss. It is truly sad news as Monty seems to have been an all around great guy. RIP Monty Johnson!

I really like how you have stacked the Aluminum ingots. It seems your shop is now turning into the Fort Knox of Aluminum world :thumbup:

PS
And since your shop now is the Fort Knox of Aluminum, chances that you will score more high quality free drills such as Milwaukee etc, are even higher. You might even want to place an ad in the BurglarsRUs.com and invite such donations for a good cause. :lol_hitti

Thanks, I know Monty is visiting with Bob's invisible friend.

Ford knocks, you say? Makes sense to me, Ford knocks aluminum blocks.

I had not thought of advertising in BurglarsRUs, I'm afraid I would anger some of my friends who are regulars there.

Sorry for your loss Andy. We learn a lot about living from you in this thread, and also about how to handle a tragic event like this. You mention celebrating Monty's life. Which is the point, rather than dwelling on the end. Thank you for another lesson.

-Derek

Such kind words, thank you sir.:bowdown: Monty was an amateur historian and a lot of interesting information went with him. Whenever I would plow on of my bottom fields he would come and walk it for arrowheads after a rain. These fields by the creeks were full of campgrounds and hunting areas.

When the dust settles it is time to help his widow.

He was also an excellent sawyer, didn't just own a sawmill. In about 96 I mentioned to him my new company was looking for bricklayers. He said "I do that". I said refractory firebrick for refinery service. He said "I do that". He came and interviewed and worked for us a few years, became a foreman almost immediately. Yes, he could do that.

Thanks for your comments, and thanks again to all the visitors and well wishers.

Life goes on, life is for the living. So I did some casting today. But first, free tools.

I have a friend who is selling her mom's house. Her mom recently moved to an assisted living facility. They had bought a riding lawn mower last summer to mow her yard with and I offered to buy it. When I went to pick it up "do you want any of this stuff?" Her father's tools, mostly old USA made. He wasn't a mechanic, but still nothing that should be thrown away.

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A couple of good Disston hand saws.

Including a 3-1/2" Wilton Cadet vise, 8134.

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Pretty cool, I can find a place for that. And lots of extension cords. Neither she nor her brother nor their kids were interested. :willy_nil

Then to casting.

First the foam patterns got some extension of the feeder system as the guys on the casting forum thought they wouldn't fill.

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What do they know?

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A lot apparently. It only filled about 6" past the feeder. I need to make major modifications to the other one. But at least the parallel lugs at the bottom filled nicely.

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I did cast another hammer head and trivet while I was working.

You really only learn through failures so today was successful. Only there are more lessons than days left.

Thanks for looking in!
 

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oldironfarmer

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Oh, that Cadet will clean up nicely. :beer:

It seemed nice for free.

I added a big ugly feeder to my other clamp piece and poured it. I was in a hurry and didn't get it buried deep enough so I put on some sideboards and stacked the sand up.

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While digging in the sand I found the end off the first clamp.

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It is melted inside but the aluminum was just too cool to flow.

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And because the sand was shallow the aluminum broke through and came up to the surface, lighting the box on fire.

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It was exciting for a second. I kept scraping it away and covering it with sand to limit the flames.

However, the pattern filled just fine. The break through drained metal from the top of the feeder, but it did not affect the part.

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Hurry up and screw up. I'm a lucky duck.

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Time to make another pattern.

Let's see, I did get another lesson. On hurrying. Oh yeah, I've had that lesson before. Guess it didn't take.

Thanks for stopping by!
 

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bolensboneyard

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Nov 22, 2013
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South East
Andy your pictures gave me an idea. Why not pour a fire and hill/mound and give the little buggers a taste of their own medicine. Make a nice trophy.
 

RickP

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Jan 15, 2013
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Annapolis, MD
Good learning experience - I like your way of looking at it that way. At least the second pour worked, even if it was a bit exciting. I'm constantly creating "good learning experiences" for myself!

For the next pour, could you fill from both ends? (or have two fill tubes from one central pour location) I'm not sure about the terminology, or what's possible with casting, but it sure is fun watching your adventures while you learn.
 

drivesitfar

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Pacific Northwest
Andy: looks like you are having a good time learning how to make bigger items. in the one picture I see a lot of aluminum scrap so guessing you'll need more shelving just for your ingots and muffins once you melt that bunch?

does everybody in town know you are melting metal and do they all drop off their scrap to you or maybe just save it in a pile until you get a chance to stop by and pick it up?

the pharmacy shelving is looking pretty good. are you spray painting or brushing the paint on?

cheers and hope you have a great day!!
 

gman007

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gman007

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Andy
I submit to you that there was no screw up of any kind here! It was in fact by design and the great result attest to this fact! (well since I constantly screw up, if once in a while I get lucky and things work out I take full credit for it but for some strange reason my wife never believes me when I say what happened was intentional :headscrat :dunno: :bounce:)

The piece looks great :thumbup:
 
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oldironfarmer

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Now you've learned you can get away with it.

Agreed that the price was right on the Wilton.

Failure does help you learn. The feeder sure did the trick.

Andy your pictures gave me an idea. Why not pour a fire and hill/mound and give the little buggers a taste of their own medicine. Make a nice trophy.

I'd have to have fire ants, sadly, I don't have any.

I've seen the videos of people pouring aluminum down large ant hills. They make cure sculptures. I've just never been interested.

Good learning experience - I like your way of looking at it that way. At least the second pour worked, even if it was a bit exciting. I'm constantly creating "good learning experiences" for myself!

For the next pour, could you fill from both ends? (or have two fill tubes from one central pour location) I'm not sure about the terminology, or what's possible with casting, but it sure is fun watching your adventures while you learn.

A bad learning experience involves visiting the ER and/or filing an insurance claim.

Filling from both ends is sometimes done in commercial foundries. It must be done simultaneously to avoid a cold shut where the two streams meet. You need two crucibles and two people to pour simultaneously. If you pour one end, then the other, the first metal front is sure to firm up before the second front meets it, so a cold lap will likely result. I've never tried it, but believe those who say it is not a good idea.

Andy: looks like you are having a good time learning how to make bigger items. in the one picture I see a lot of aluminum scrap so guessing you'll need more shelving just for your ingots and muffins once you melt that bunch?

does everybody in town know you are melting metal and do they all drop off their scrap to you or maybe just save it in a pile until you get a chance to stop by and pick it up?

the pharmacy shelving is looking pretty good. are you spray painting or brushing the paint on?

cheers and hope you have a great day!!

I think the scrap you are seeing are power transmission line cross arm brackets. They are nice, heavy, and clean. They only need cut up, no reason to melt them for ingots.

Several people are saving scrap and bringing it to me. I feel very blessed people give me their scrap.

I would love to spray the shelving but it will be rolled and brushed. My paint booth is not ready and I don't want to get overspray on an old car.

Had a great day!

Oh no! Another rabbit hole to explore. Just google "fire ant sculpture" and be amazed.

Pretty cool. It's a hot idea.

BB
it has already been done :beer:

Among other YouTube videos on the subject here is one

Casting a Fire Ant Colony with Molten Aluminum

but Andy probably will consider this a waste of sacred Aluminum :bounce:

It's not wasted if you dig it all out and recycle it. But it does not really turn me on.

Andy
I submit to you that there was no screw up of any kind here! It was in fact by design and the great result attest to this fact! (well since I constantly screw up, if once in a while I get lucky and things work out I take full credit for it but for some strange reason my wife never believes me when I say what happened was intentional :headscrat :dunno: :bounce:)

The piece looks great :thumbup:

You're too kind. Recovering from screwups is a basic tenet of woodworking. But there was no recovery here, just luck.

Your wife may very well believe you, she just thinks it would be stupid to let you know and watch you try to push the envelope.

Short update. I was cleaning up a little (very little) and came across a 2" foam cylinder. Put it on the hot wire cutter and spun it slowly as iI was feeding it.

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I think I could cast a screw pump. It's like a short section of flighting.

Got the pattern remade. Here it is with a big runner and small gate to assist in keeping it aligned.

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That's the way I gated the successful one.

Mudded it in and it will be ready to cast tomorrow.

Thanks for the visits!
 

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shortykorte

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Tallahassee, Fl
Andy, I stayed at a Holiday Inn Express last night so I think I can give you some educated guesses. Would it be beneficial to have an exit gate/port on the long end. I’m thinking this will reduce pressure, let things vent and let you know that aluminum flowed all way through.


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Guster

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Messages
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Location
Auckland, New Zealand
I'm impressed you pulled off that cast with lost foam. Shows how versatile simple techniques can be so long as you get the basics right. For a small time caster even a small failure now and then is nothing lost but time and a learning opportunity. Keep pushing the envelope Andy. :thumbup:

Those helix curly fries show some serious finger dexterity. I've done enough hot wire cutting to know that was not easy. Plus now I need to go see what a screw pump is all about.
 
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oldironfarmer

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Excellent progress and recovery Andy.

Always enjoy your entries and also post action analysis

Thanks, Rian! Always nice to have you stop by, either cyberically or physically.

Andy, I stayed at a Holiday Inn Express last night so I think I can give you some educated guesses. Would it be beneficial to have an exit gate/port on the long end. I’m thinking this will reduce pressure, let things vent and let you know that aluminum flowed all way through.


Sent from my iPhone using The Garage Journal mobile app

Hey Shorty!! Like that free breakfast?

Lost foam casting has very different parameters than other casting methods. In lost foam the advancing metal front vaporizes the foam which creates a little pressure between the metal and the solid foam. The metal never actually touches the foam, radiant energy vaporizes the foam and the vapor pressure helps maintain the integrity of the advancing liquid. The vapor also quickly absorbs into the sand bed. This takes place through the sheetrock mud as well. But because the foam pattern is buried in compacted sand there is no way for the vapor to escape out the end of the pattern until the foam has melted to the end.

I have seen people who use straws to provide a vapor path to the surface (similar to your idea) but they are not really thinking the process through. It takes energy to vaporize the foam (and glue and wax) so the melt needs to start a little hotter than if it were being poured into an empty cavity. Similarly you want to pour into foam from the top while into an empty mold it is best to come in from the bottom, or the side.

It would let you now the metal had reached it's destination, but with lost foam you pour until it's full and quits taking metal. Knowing it had filled would be gratifying but there would be nothing you could do to recover other than perhaps pour less metal.

Are you about ready for a burner?

I'm impressed you pulled off that cast with lost foam. Shows how versatile simple techniques can be so long as you get the basics right. For a small time caster even a small failure now and then is nothing lost but time and a learning opportunity. Keep pushing the envelope Andy. :thumbup:

Those helix curly fries show some serious finger dexterity. I've done enough hot wire cutting to know that was not easy. Plus now I need to go see what a screw pump is all about.

Thanks, Guster! Of course getting the basics right is paramount, but you also find most patterns present their individual challenges. I like to think of failures as providing more material to feed the crucible next time.

The helix was really not that hard to cut, just roll with the flow and try to maintain a consistent helix angle. I need to make a guided tool with a long pitch drive screw if I decide to make many of them to get consistent results. I did keep the cut a little off center so one piece has a hole through and the other is solid. The hole seems surprisingly straight too.

We had the funeral today, 100 people at our funeral dinner. Monty was interested in casting and I had an hour after feeding and fixing breakfast so I hustled out and poured the second clamp arm in respect to my friend.

Today's Screwup

I couldn't seem to pour the metal fast enough to keep the sprue from collapsing. My entry cone was too small and I spilled metal at first tip and was trying to not add to the lava flow. Then as I was about done I saw the sand collapse away from the sprue. This can't be good.

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But not too bad. Apparently because I was not pouring as fast as the advancing metal front (with lost foam you start pouring then is slows and hesitates, for a moment, then the metal begins flowing faster. Don't know what makes the hesitation, but you have to be on your toes to speed the pour rate up as the metal level falls) some of the metal fed out of the top runner. That caused the sand collapse. Only the runner appears to not be filled, the casting looks good.:thumbup:

Lesson for today, I am one lucky duck.

Thanks for dropping in. Like the molten aluminum. You drop in and something good comes of it.
 

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bolensboneyard

Well-known member
Joined
Nov 22, 2013
Messages
3,074
Location
South East
Andy love your explanation of what happens with lost foam. Now I understand it better. However, I cannot understand why I keep typing the letters that are on the opposite side of the keyboard from where my brain is telling them to type.?
 

gman007

Well-known member
Joined
May 17, 2017
Messages
2,730
Location
West Michigan
Andy
I believe even if there is an element of luck involved, the fortune generally favors the skilled and talented. Very nicely done :thumbup:

And thank you again for your as per usual detailed photos and great explanations. Your informative narratives are always educational :bowdown:
 
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