Above 1200 Sq/FT Cleaning Up My Shop

[bolensboneyard]

Fascinating!

 

[RickP]

I've been working on making cast aluminum pipe, 1-1/2" OD, 1/4" wt on a challenge. A guy said I couldn't sand cast four of them and have them not leak for 30 min at 30 psi with antifreeze mix inside.
...
No weeping anywhere except the other guy.

Hasn't that guy been following along with your casting adventures? He's definitely not a GJ member!

Nice casting on that pipe - looks good. It seems like it would be a shame to melt them down right away - could you free up some storage space above the ingot shelf in case you find another use for them someday? (after all, you have been known to repurpose things every once in a while )

 

[oldironfarmer]

Have you thought about investment casting for the gear?

I have some 3D printed change gears on my lathe and I'm hoping they last so I don't need to move on to casting them (I'd probably go with investment casting so I can burn it out ahead of time).

That would be called lost PLA casting in this case. It is supposed to work well, but I'm really trying to green sand cast this because traditionally the gear would have been sand cast. Investment casting would show all the printer patterns so I would need more preparation. I have some investment but not sure it's good for iron temperatures. I need to read up on that.

Very cool that you are getting service out of printed change gears. Are they ABS?

Brass change gears would work well, one would think.

Fascinating!

Of course the idea of starting this craft was to make machine parts.

Hasn't that guy been following along with your casting adventures? He's definitely not a GJ member!

Nice casting on that pipe - looks good. It seems like it would be a shame to melt them down right away - could you free up some storage space above the ingot shelf in case you find another use for them someday? (after all, you have been known to repurpose things every once in a while )

He's not on GJ, that I know of. But he is a very smart and capable guy. Does some amazing work. It was a friendly challenge.

Thanks for the kind words!

I won't melt them down anytime soon. JB had a great idea, I may make a few reservoirs for myself as well. The purple car has a commercial one on it but I should have cast my name in the side.

Each one pray for Stephen Church and his family.

 

[Guster]

You can get investment that is made for cast iron though I have not seen any for the block method. The slurry type is not cheap and a very tedious process.

Silica sand might be the way to go as it is more conducive to pulling patterns like that. Epoxy sand might be another way to go but I would heavily mold release the part so it won't bond into the sand.

Alternatively if the teeth are dividable by an even number so you can make a composite block mold pattern? For example if it is dividable by 4 you print a quarter and make a small block mold for each quarter - like a core mold used on the outside. It would be fiddly to assemble but perhaps easier to manage.

WW1/2CD?

Each one pray for Stephen Church and his family.

Amen!

 

[oldironfarmer]

15 teeth are unfortunately indivisible by 4. I got a drag portion draft version printed today. Cope started.

I learned something new today. A nice sharp file smooths PLA better than sandpaper.

Also turned up a brass punch from what I cast the other day.

Painted dried sanded and rammed up a mold.

Pulled the sand out three times.

The "wetted" perimeter of each tooth is much longer than the tip to top distance and the sand wants to shear in a circle. I did a little better not ramming the sand very tight.

I am going to sand the teeth some more to try to get them slicker and then wax them. Ram the sand a bit harder but not like I usually do and it may work.

I had to print a new stripper plate as my first one, at 102% was too small. New one is still printing at 106%.

First failure was aggressive tapping of the pattern and fractured the sand in a circle. Second failure was less aggressive tapping and used a ******** on it. I think that set the sand in the teeth. Third failure was a little better with letting an iron bar bounce off the center hole. Last failure (last picture) the sand was not rammed hard enough but stayed put for the most part. Not hard enough to pour against, I don't think.

Plan forward is to ram firmly, gently setting the sand between each tooth, and use the stripper plate.

 

[jblnut]

Once you starting doing cast iron casting just think of all the things you'll need to make to awaken your entire herd of ageless iron that is sleeping in the pasture

Not to mention that I will probably try to coax you into casting a much needed crank for my drill press I cannot seem to find anywhere.

 

[cbacres]

Nice work on the punches. You now have me saving aluminum to melt down some day. I'm storing it next to the steel that I plan for n using when I get around to trying my hand at blacksmith stuff.

Now I need to save up for bronze punches.

Great work, enjoy reading.

 

[oldironfarmer]

Once you starting doing cast iron casting just think of all the things you'll need to make to awaken your entire herd of ageless iron that is sleeping in the pasture

Not to mention that I will probably try to coax you into casting a much needed crank for my drill press I cannot seem to find anywhere.

That herd of aged iron is my raw material stash.

Is that the crank to lift the table? Brass wouldn't do?

I have a band saw guide to finish.

Nice work on the punches. You now have me saving aluminum to melt down some day. I'm storing it next to the steel that I plan for n using when I get around to trying my hand at blacksmith stuff.

Now I need to save up for bronze punches.

Great work, enjoy reading.

Thanks for stopping by! You have no idea what joy it gives me to lead another astray. Soon everything starts to look like raw material. I was in Town & Country Hardware the other day and saw the brass fittings, thinking, they'd sure melt nicely and I could make my own. Nothing wrong with me.

 

[cvairwerks]

Andy: I wonder if you could ram the sand just enough to get a decent setting around the pattern, then pull it, recoat with release agent and slide it back in and ram to finish point.

 

[bolensboneyard]

Great job Andy.

 

[oldironfarmer]

Andy: I wonder if you could ram the sand just enough to get a decent setting around the pattern, then pull it, recoat with release agent and slide it back in and ram to finish point.

It's way too fragile for that. One touch with anything hard and it crumbles off. If the pattern was on a rigid guide, maybe. The interesting thing, though, is that if you can get the sand to stand the pattern being withdrawn it will hold up to molten metal. The metal is much less intrusive than a solid object.

Great job Andy.

Thanks, Bobby!

 

[Craptain]

Could you use Sodium Silicate to firm up the mold? It works perfectly for cores, so I think it would give you the strength you need for the details.
I haven't done any casting, so maybe I am off base here.

Sent from my SM-G930T using Tapatalk

 

[oldironfarmer]

Could you use Sodium Silicate to firm up the mold? It works perfectly for cores, so I think it would give you the strength you need for the details.
I haven't done any casting, so maybe I am off base here.

Sent from my SM-G930T using Tapatalk

What do you know?

I decided to try it, but don't want to use up my green sand, thought I'd just make a mold out of core sand.

Started with a 4" PVC pipe for a mold, as long as the thin gear is thick.

Packed it full of mixed sand, cured it, and was able to tap the pattern out, very gently. About 50 taps before I say it move, and another 20 to get it out.

Handling it I broke it. Not rough handling, it was very fragile. So I made a larger form out of a piece of flashing and rammed the larger end. Lots of vents to help the CO2 get in, and three alignment holes.

Put it in my CO2 box and cured the sand. Loosened the form and raised it like a slip form and used lots of parting compound to put the other pattern on top.

Then cured everything together.

This is looking real good.

I didn't want to use a hard sand, I wanted to do green sand casting but after the kind suggestion decided why not just go ahead and do it. I still think I can do green sand and may try it after this is cast.

 

[oldironfarmer]

VERY carefully took the two halves apart.

That's the broken first mold upper right.

Tapped forever on the larger one and after several minutes realized it had moved a few thousandths. A good hard blow would break the hard sand.

Got the other one out and it's looking good.

Test fit.

Success!! Now if I can just ram them into the flasks without breaking them. This is going to be walking on eggshells all the way.

 

[y'sguy]

Great Job Andy!, Glad you have the patience for this. But also your experience gained!

 

[dchance]

Andy, looks like success. The things we learn when we have problems.

Dwight

 

[Redwolf947]

Was following along on the other thread and thought you might post here. Looks great. I hope that it works out.. cool..

 

[Grizz1963]

Love your new Signature or is that Salute, Andy.

 

[oldironfarmer]

Forgive me for not responding while I grieve my friend Stephen Church.

I cherish his hand addressed package label to me.

 

[Redwolf947]

Completely understand. 1/2cup will be missed. Bless Stephen and his Family.

 

[Coolabah]

Completely understand. 1/2cup will be missed. Bless Stephen and his Family.

Well said, Redwolf.
I think this has brought home to me for the very first time how you can very much "know" someone online -( I am older than the internet LOL, and don't do Facebook etc ) and how much I valued my online contact with 1/2 cup/Steve.I hadn't thought about it before , but his (and a few others) are threads I check more than daily looking forward to any updates. I am even more sad that most of us (?) didn't realise that his last re-admittance to hospital was any more than a minor inconvenience "until Steve was back on track for his QST".
@ Andy : I am very sad too.

 

[rannoch]

That would be called lost PLA casting in this case. It is supposed to work well, but I'm really trying to green sand cast this because traditionally the gear would have been sand cast. Investment casting would show all the printer patterns so I would need more preparation. I have some investment but not sure it's good for iron temperatures. I need to read up on that.

Very cool that you are getting service out of printed change gears. Are they ABS?

Brass change gears would work well, one would think.



Of course the idea of starting this craft was to make machine parts.



He's not on GJ, that I know of. But he is a very smart and capable guy. Does some amazing work. It was a friendly challenge.

Thanks for the kind words!

I won't melt them down anytime soon. JB had a great idea, I may make a few reservoirs for myself as well. The purple car has a commercial one on it but I should have cast my name in the side.

Each one pray for Stephen Church and his family.

The gears are for a Barnes no.5 lathe and I haven't much of an occasion to use them, currently PLA but given the low speeds of the lathe I think bronze/brass would work quite well.

I worked at a lost wax titanium casting facility for a little while and eventually want to do some casting at home (not titanium though).
Love what you're doing with the sand, the forms for the gear are looking good.

 

[oldironfarmer]

I have had some QST and am thinking of Steve every moment.

It is a shame he never had the opportunity for retirement and full time QST. However he was very interested in his work and bringing along young employees, training them. What an excellent example to work under!

 

[Farmall450]

Completely understand. 1/2cup will be missed. Bless Stephen and his Family.

So sorry to hear about him.

 

[TwoBytes]

I have had some QST and am thinking of Steve every moment.

It is a shame he never had the opportunity for retirement and full time QST. However he was very interested in his work and bringing along young employees, training them. What an excellent example to work under!

I never met Steve in person, but I'm deeply saddened by his passing. I can only imagine what his family, close friends and coworkers are going through.

He was an inspiration, and he has left a lasting impression on this little black duck.

(Signature used proudly with OIF permission)

 

[CraigRK]

I have had some QST and am thinking of Steve every moment.

It is a shame he never had the opportunity for retirement and full time QST. However he was very interested in his work and bringing along young employees, training them. What an excellent example to work under!

Andy, I came to know Steve only through this thread and your comments, but now see his mark on any and all other threads I peruse.

I can see what has been said about him always finding the good to say in his comments. It is very sad when someone who has affected so many so deeply passes, but I like to try to take that on board as part of the their legacy.

I get your point about the QST and thinking about Steve. I lost a friend 5 years ago with whom I had spent many quality shop hours. To this day I think about him whenever I am tinkering away on my various projects. No doubt influenced in part by the fact that I was able to acquire some of his tools at the time, so a piece of him lives on in those, like a piece of Steve will continue to live on in the posts he made here.

My thoughts (as with many others) go out to his family, but also to you and the others who were so privileged to consider him a friend.

PS: Flights are booked for August/September, I'm hoping we'll make it to OK!

 

[Guster]

I have had some QST and am thinking of Steve every moment.

It is a shame he never had the opportunity for retirement and full time QST. However he was very interested in his work and bringing along young employees, training them. What an excellent example to work under!

I think it is one of the great ways we will all remember him for. Such a universal expression of why we enjoy our garages. Even my wife now knows what I mean when I say I need a little QST this weekend.

Saw the video of the gear casting and it came out great. The charge looked more the hot enough on the video. Going by the glow of the furnace and the roar of the burner you had it running wide open throttle

I was thinking you could CNC router out a lost foam pattern to use with green sand as a lost foam pattern for it too which would be a bit less fiddly than the 3D printed pattern.

 

[Grizz1963]

Andy, I came to know Steve only through this thread and your comments, but now see his mark on any and all other threads I peruse.

I can see what has been said about him always finding the good to say in his comments. It is very sad when someone who has affected so many so deeply passes, but I like to try to take that on board as part of the their legacy.

I get your point about the QST and thinking about Steve. I lost a friend 5 years ago with whom I had spent many quality shop hours. To this day I think about him whenever I am tinkering away on my various projects. No doubt influenced in part by the fact that I was able to acquire some of his tools at the time, so a piece of him lives on in those, like a piece of Steve will continue to live on in the posts he made here.

My thoughts (as with many others) go out to his family, but also to you and the others who were so privileged to consider him a friend.

PS: Flights are booked for August/September, I'm hoping we'll make it to OK!

I will reiterate what Craig mentioned about his very good friend.

Much of what he, or the two of us do even now, are referenced to his late friends legacy.

We celebrate their lives daily, and this is the best we could do for them.

Look after yourself friend.

 

[Toothaker]

How ya doin' Andy?

 

[Redwolf947]

Hey Andy, any updates on the gear casting. I think we all would like to know..

Hows the pups and the farm critters err cows. Is the bull still hanging around? Drive any tractors lately?
Hope all's well..,
Mike

 

[oldironfarmer]

Great Job Andy!, Glad you have the patience for this. But also your experience gained!

Thanks! The gear is trying my patience. However I am learning a lot as I go along.

Andy, looks like success. The things we learn when we have problems.

Dwight

I almost think you only learn when you have problems. Otherwise it seems deceptively easy, then Wham!! You suddenly know nothing.

Was following along on the other thread and thought you might post here. Looks great. I hope that it works out.. cool..

Thank you. Partial success.

Love your new Signature or is that Salute, Andy.

Thanks, Rian. Though I never met 1/2 Cup, he became a good friend. His passing was unusually hard on me. I very much wanted to meet him in person.

 

[oldironfarmer]

Completely understand. 1/2cup will be missed. Bless Stephen and his Family.

It has been hard to return to Garage Journal without Steve watching my every move. I do believe his dear family has been blessed by the outpouring on Garage Journal. It is a true testimony to the impact he had over the internet.

Well said, Redwolf.
I think this has brought home to me for the very first time how you can very much "know" someone online -( I am older than the internet LOL, and don't do Facebook etc ) and how much I valued my online contact with 1/2 cup/Steve.I hadn't thought about it before , but his (and a few others) are threads I check more than daily looking forward to any updates. I am even more sad that most of us (?) didn't realise that his last re-admittance to hospital was any more than a minor inconvenience "until Steve was back on track for his QST".
@ Andy : I am very sad too.

I have met a few people from Garage Journal and each was the same as online. I've not met my Nigerian Prince benefactor but hope to very soon.

I'm pretty callous and was surprised how deeply saddened I was at Steve's passing. And still am.

The gears are for a Barnes no.5 lathe and I haven't much of an occasion to use them, currently PLA but given the low speeds of the lathe I think bronze/brass would work quite well.

I worked at a lost wax titanium casting facility for a little while and eventually want to do some casting at home (not titanium though).
Love what you're doing with the sand, the forms for the gear are looking good.

Thank you, it is a learning experience.

Next step on your lathe gears would be to try ABS, it is much stronger.

Nice!!!!!

Thank you.

 

[oldironfarmer]

So sorry to hear about him.

Thank you.

I never met Steve in person, but I'm deeply saddened by his passing. I can only imagine what his family, close friends and coworkers are going through.

He was an inspiration, and he has left a lasting impression on this little black duck.

(Signature used proudly with OIF permission)

Deeply saddened and lasting impression are the words.

Andy, I came to know Steve only through this thread and your comments, but now see his mark on any and all other threads I peruse.

I can see what has been said about him always finding the good to say in his comments. It is very sad when someone who has affected so many so deeply passes, but I like to try to take that on board as part of the their legacy.

I get your point about the QST and thinking about Steve. I lost a friend 5 years ago with whom I had spent many quality shop hours. To this day I think about him whenever I am tinkering away on my various projects. No doubt influenced in part by the fact that I was able to acquire some of his tools at the time, so a piece of him lives on in those, like a piece of Steve will continue to live on in the posts he made here.

My thoughts (as with many others) go out to his family, but also to you and the others who were so privileged to consider him a friend.

PS: Flights are booked for August/September, I'm hoping we'll make it to OK!

Very well put, Craig.

I truly hope you can make it to Oklahoma again this year but I understand how busy your trips are. Especially with the time Rian must spend in each establishment chatting up the birds.

I think it is one of the great ways we will all remember him for. Such a universal expression of why we enjoy our garages. Even my wife now knows what I mean when I say I need a little QST this weekend.

Saw the video of the gear casting and it came out great. The charge looked more the hot enough on the video. Going by the glow of the furnace and the roar of the burner you had it running wide open throttle

I was thinking you could CNC router out a lost foam pattern to use with green sand as a lost foam pattern for it too which would be a bit less fiddly than the 3D printed pattern.

Thanks, Guster. Your wife would have approved of the organization in Steve's shed.

For those who missed the video, here's the completed gear. It did not quite pour full and the gate froze on me and I finished pouring into the riser. Not a good thing to do but it came out surprisingly well.

I will reiterate what Craig mentioned about his very good friend.

Much of what he, or the two of us do even now, are referenced to his late friends legacy.

We celebrate their lives daily, and this is the best we could do for them.

Look after yourself friend.

Very well put, Rian. We will all remember Steve.

The good news is when I'm down, or mad, I get busy.

How ya doin' Andy?

Doing good Mitch, sorry for the absence.

Hey Andy, any updates on the gear casting. I think we all would like to know..

Hows the pups and the farm critters err cows. Is the bull still hanging around? Drive any tractors lately?
Hope all's well..,
Mike

Thanks for the interest Mike. The gear came out ok, not great. Fresh out of the sand.

Compared to the pattern.

Ready to mail.

A little video for those interested.

Cast Iron Gear Pour

My heartfelt thanks for all the concerns while I've been occupied.

 

[don long]

That gear is pretty good Andy!!!
I enjoyed the video

I won't be melting anything soon (way too much protection to have to wear)

 

[Grizz1963]

Excellent work, still you are constantly learning.

Video is clever with two cameras.

Love the editing too.

 

[Coolabah]

It has been hard to return to Garage Journal without Steve watching my every move. I do believe his dear family has been blessed by the outpouring on Garage Journal. It is a true testimony to the impact he had over the internet.



I have met a few people from Garage Journal and each was the same as online. I've not met my Nigerian Prince benefactor but hope to very soon.


Thank you.

...welll , that's me stuffed. I am as every bit irritating in real life.
At least 1/2 cup tolerated me ! What am I going to do now ??

 

[oldironfarmer]

That gear is pretty good Andy!!!
I enjoyed the video

I won't be melting anything soon (way too much protection to have to wear)

Thanks, Don!

It's really not too bad doing it in teh heat. After all, handling 2,600F metal on a 30F degree day or 105F day, not much difference.

Excellent work, still you are constantly learning.

Video is clever with two cameras.

Love the editing too.

It's has great recreational value, and you can make stuff too. Kind of like ***...

...welll , that's me stuffed. I am as every bit irritating in real life.
At least 1/2 cup tolerated me ! What am I going to do now ??

Many people were happy to see me retire.

My advice is to post your good times on your friend's thread.

 

[TwoBytes]

It's has great recreational value, and you can make stuff too. Kind of like ***...

 

[bolensboneyard]

Enjoyed the video Andy. It amazes me the iron stays fluid so long.

 

[oldironfarmer]

Thanks, Bobby. It is a steep learning curve. I've poured another one today and had the runner freeze again. It must be me. If figure it's not hot enough.