Help, Need to cast a replica

[383]

I'm using some sliding door hardware in my basement that is over a hundred years old. I have all of the parts except for one end bracket. I could use the one that I have to create a mold but I've never done that. It doesn't need to be strong, I have enough other brackets to support the weight of the door. I make lead fishing lures, would it work to make a mold with plaster and pour the piece with lead, or is there a better way to accomplish this? Here are some pics of the part I need.

https://goo.io/nJwYmJ

Or maybe one of you have one of these laying around................

 

[lilredex]

Lead is not going to stand up for long. I'd fabricate one from steel (if you can weld). Pretty easy project. If you really want to cast something, use aluminum. Using that piece as a pattern will yield a part slightly smaller, if that matters.

 

[EdT]

By the time you cast one, you could probably fab one up from a piece of angle iron. Is the little X shaped piece actually required to be that shape or is it a concession to the casting process to maintain more uniform wall thickness (and save a little material). If a cylindrical shape would do, it would be pretty easy to make especially if you don't need the stiffening rib on the outside.

 

[Muggzy]

You sound like you're able to make the mold. And as lilredex said, "lead won't work", it's way too soft. If you search king of random on YouTube, he's got a great video on making a small furnace to melt aluminum. I've been waiting til I get some time to play in a few weeks to try if myself.

Sent from my KFOT using Tapatalk

 

[scrumpy]

In the meantime it may save some work if you take a good picture on a light plain background and the drag the pic into a google search bar and see if one is available using image search. Just another option. Unless you want to try your hand at casting of course.

 

[383]

Lead is not going to stand up for long. I'd fabricate one from steel (if you can weld). Pretty easy project. If you really want to cast something, use aluminum. Using that piece as a pattern will yield a part slightly smaller, if that matters.

That is an excellent idea that I hadn't thought of. I just checked my scrap metal pile and have a piece of angle that is almost perfect. my metal working tools are sparse, but I should be able to eventually get the correct shape with an angle grinder.

By the time you cast one, you could probably fab one up from a piece of angle iron. Is the little X shaped piece actually required to be that shape or is it a concession to the casting process to maintain more uniform wall thickness (and save a little material). If a cylindrical shape would do, it would be pretty easy to make especially if you don't need the stiffening rib on the outside.

The x shaped piece is not seen when the track is assembled, it should be easy to find something that matches the inside diameter of the track.

You sound like you're able to make the mold. And as lilredex said, "lead won't work", it's way too soft. If you search king of random on YouTube, he's got a great video on making a small furnace to melt aluminum. I've been waiting til I get some time to play in a few weeks to try if myself.

If making it out of angle doesn't work, I'll give that a try.

In the meantime it may save some work if you take a good picture on a light plain background and the drag the pic into a google search bar and see if one is available using image search. Just another option. Unless you want to try your hand at casting of course.

That is an excellent idea, I forget about google searching images. That would definitely be faster and easier than making one. I do like a challenge though, if I do end up making it.

Thanks for the suggestions, I'll post the pics of whatever solution I end up with.

 

[j p smith]

Can the x shaped piece be round, if so easy to make using the angle and a piece of round bar

 

[drivesitfar]

383: some of the guys use molds and JB Weld to make repairs and parts for their old vises that might work for your little part if you can make a mold. here's a thread i'm reading where a member (Mark in Indiana) is repairing a broken foot on an old cast vise's swivel base.

http://www.garagejournal.com/forum/showthread.php?t=331362

good luck and i'll check back to see what you did to solve your issue and i wish i had a part to mail you.

any pictures of the door to post since we all like old cool stuff?

 

[chris_c]

Maybe something LIKE a hitch off a lawn tractor.

http://www.farmparts4less.com/universal-heavy-duty-hitch/

Minimal extra fabrication

 

[My Old Tools]

These guys will cast from your original, in cast iron....cheap. We (old tools people) use them to replicate parts. They are Amish, very fair, do good work, etc.

Cattail Foundry
Emanuel J. King
167 W. Cattail Road
Gordonville, PA 17529
(717) 768-7323

 

[383]

Can the x shaped piece be round, if so easy to make using the angle and a piece of round bar

The x shaped piece is not visible when it's installed, bar or pipe should work.

383: some of the guys use molds and JB Weld to make repairs and parts for their old vises that might work for your little part if you can make a mold. here's a thread i'm reading where a member (Mark in Indiana) is repairing a broken foot on an old cast vise's swivel base.

http://www.garagejournal.com/forum/showthread.php?t=331362

good luck and i'll check back to see what you did to solve your issue and i wish i had a part to mail you.

any pictures of the door to post since we all like old cool stuff?

Thanks for the link. I had thought about JB Weld, but didn't know if it would work. That may be easier than fabricating it from angle with my limited tool collection.

I haven't built the door yet, but it will be a 4' wide version of this hinged door that I built for another wall in the basement.

Here is the trolley hanger that goes with the track.

Here is the link to my build thread if you are interested. http://www.garagejournal.com/forum/showthread.php?t=329978

Maybe something LIKE a hitch off a lawn tractor.

http://www.farmparts4less.com/universal-heavy-duty-hitch/

Minimal extra fabrication

Thanks for the link, that does look very similar.

These guys will cast from your original, in cast iron....cheap. We (old tools people) use them to replicate parts. They are Amish, very fair, do good work, etc.

Cattail Foundry
Emanuel J. King
167 W. Cattail Road
Gordonville, PA 17529
(717) 768-7323

It is good to know that you can still have obsolete parts made. If I strike out on making my own that is a great option.

 

[drivesitfar]

383: nice looking door. i'll keep checking to see which option you picked and there are some good ideas already you've collected.

good luck

 

[ovrrdrive]

I've seen some molding techniques that work pretty well and don't seem over complicated to do. I believe it's a silicone mold, then wax in the silicone, then a sand/wax displacement pour using your metal of choice...

Just did a quick google search on it and the correct term is 'lost wax molding' and there are a variety of different techniques detailed on youtube and a bunch of websites.

I bet something small like that wouldn't be too terribly complicated to replicate...

 

[kbs2244]

Do a search for a 3D printer service
They are printing in metal now.
They should be able to scan in your part and dup it.

 

[383]

I went with the angle iron option. My welding skills aren't on par with my woodworking skill, so I cheated and made the reinforcing piece out of JB Weld.

It's not an exact match, but the two brackets will be on opposite ends of an 8' track, so it's close enough for me.

Thanks to everyone for the suggestions.

 

[lilredex]

Looks OK, but the first time that bracket flexes (if it does) your JB gusset is going to crack and fall off. Probably a waste of time making it. I'd make one up and weld it on.........not that hard to do.

 

[383]

Looks OK, but the first time that bracket flexes (if it does) your JB gusset is going to crack and fall off. Probably a waste of time making it. I'd make one up and weld it on.........not that hard to do.

I used 1/4" angle, and I'll have another bracket within a foot of the end of the track. No heavier than my door is, I'm hoping it will be OK. The gusset is just there for looks.

You are right, welding it on wouldn't be that hard. But, no better than my welding skills are, grinding the mess out of the inside corners would ****.

If it does flex and fall apart, then I can try to weld it.

 

[drivesitfar]

383: it looks good and hope it works. looks like all you need to do is drill a couple holes and install it.

educational thread on a little part that we all need something similar every now and then.

good luck

 

[383]

If you are close to Roanoke, bring it to me and I'll weld it for you; no charge.

Ricky Joe, that is a very generous offer, I appreciate it. I'm about 1 1/2 hrs North of you.

I made the piece from 1/4" angle and the load on it will be minimal. The piece of JB Weld is just to make it look like the other one.

I was excited about the challenge of making the piece myself, if it doesn't hold up, I'll give it a try with the welder. I did weld the track support piece on the other side, but it won't be seen when it's assembled. I just don't have the proper tools to smooth out a rough weld at the intersection of an inside corner.

Thanks again to everyone for the great suggestions, ideas, and offers to help, Garage Journal is awesome!

 

[383]

I've attached the track to the track board, the end brackets aren't identical, but I'm happy with them.

 

[EdT]

looks like that turned out well.

 

[bczygan]

I can't tell which one is which!

 

[383]

any pictures of the door to post since we all like old cool stuff?

I finally built the door Saturday, still need to install a pull handle. Here is a pic.