Casting projects pics and stuff....

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Artie

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Hi all, just thought I would drop in a couple of pics and design work for your thoughts... These are parts for a final drive for an off road chassis Im building... any questions or comments, fire away please...

BrgCarrierPlug1.jpg


BrgCarrierBottom3.jpg


BrgCarrierBottom2.jpg


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30052009187.jpg


Carriercasting.jpg


Newcarrierblank.jpg
 
It looks good, did you pour it open like that or was there a (not sure the terminology) top box of sand.
I need to dig out my stuff and practice a little more, my castings dont usually look that nice.
-B-
 
poured it open for simplicities sake, (it depends upon the item being cast). This side had all the machining steps applied so it wasnt required to be any particular shape.

Just a couple of quick pics of the external housing.

Housing.jpg


Plug1.jpg


Openpour-1.jpg


Image172.jpg


CVCup.jpg


007.jpg
 
I apologise for the size of these Ill try and resize them in future.
 
Very nice, thanks for sharing! I LIKE the large photos.
 
Nice work what are you using to cut the foam. What cad program is that ? Alibre Cad??
I just took advantage of there $99 deal myself still learning.
Tin
 
cobra428 said:
Artie,
Rof} Rof} Rof} Nice work Thm:
Tony

yeah yeah ok.... yes it is funny... no i didnt mean it, sort of a non intentional comic.... 8)
 
Tin Falcon said:
Nice work what are you using to cut the foam. What cad program is that ? Alibre Cad??
I just took advantage of there $99 deal myself still learning.
Tin
gday mate, yes it is Alibre and yes I did also take advantage of their 'special'... I actually dont mind alibre.. a lot of guys bag it as being pretty cumbersome... im a novice so I know no better.... works for me...

So same size pics is ok? Ill keep doing so until otherwise is suggested.....
 
Tin Falcon said:
Nice work what are you using to cut the foam. What cad program is that ? Alibre Cad??
I just took advantage of there $99 deal myself still learning.
Tin

No its not foam... thats an MDF plug, Ill start at the beginning... I used alibre to determine the design I needed, printed of and glued this to 3mm mdf and cut out. This was screwed to 35mm particle board and an edge trim router was used to reproduce the shape. As I needed this to be twice this thick another piece of 35mm was glued to the original and the edge trim rpouter again used to make a plug 70mm thick.

Template.jpg


Plug3.jpg


This was used to form the oiled sand which was an open mold (again). All the next stuff is in green sand.... it all depends upon the item being cast as to how it is done... time and simplicity are the controlling factors...

 
oh... just had a thought (painful)... aluminium stock... I use old fire extinguishers that have been condemned.... get em cheap... (mate in the fire extinguishing testing industry... cost... nil..).

these are T6061 ali..... have to slice em up on the bandsaw and feed them into the ingot mold via the foundry... then set aside until the call comes....
27052009184.jpg


27052009185.jpg


Ingots.jpg
 
I never would have thought a fire extinguisher.
I hit up the auto repair shops and scrap yards for transmission housings and pistons.
-B-
 
The material you should use is dependant upon your final use. T6061 isnt really the best stuff to cast with, old pistons are much better as they have a failry high silicone content...6061 style ali's are more designed for stamping or forging.... however we use what we got if at all possible.... as I have some 20 unprocessed extinguishers I will need a really good reason NOT to use them.... Its rare that I have actually needed the strength of the 6061.

The housing you see here rings like a bell when tapped.... I mean really high pitched sound... I have a spare which I use to show all the guys who come around....

I close my castingmoulds when requied but generally make the item 'taller' than required and allow the sinkback to occur... only for simplicities sake.

Until now Ive used mainly oiled sand and had fairly good results but recent experiments with green sand have me wondering why I didnt do this years ago. BTW, Ive been using this foundry since 1988. Im picking up the refractory cement in a couple of weeks time to put together its replacement (throw away the charcoal and get into the gas age...)

Yes..its a forced air over charcoal burner...I havent modified it because..it works... however my local supplier of briquettes is no longer stocking them so I must change my ways (poor old girl is buggered anyway)...
 
excellent work artie. :)its great to know of another aussie caster :)
 
Great work. What I like about this post is you are producing from Cad to to finished part. Great. I am just using Alibre at the moment and using it to design my own gas fired furnace (based on many seen on youtube). So keep up the good work, I for one will follow your efforts with much interest. MM
 
Hi Artie

Great work :bow:,nothing better than doing your own casting ;D , i am working on some thing very similar for a friend , he is building a trike , still in the planning stage .
diff2.jpg

diffcase2.jpg




Regards Rob
 
Gday mate. It looks like a good start to your concept build, how are you intending to tension or adjust the chain? I see you're incorporating a differential in her as well. I ve recently contemplating redoing mine and casting the side plates in as well..... MKII I think.....

This job has come to a halt for the time being. Weve had a couple of elderly rellos pass away recently and two weddings a couple of training programs etc etc ... just isnt enough time ion any one day it seems....

Thanks for all the positive feedback guys. It does help with motivation when you (like now) cant seem to get back into it....

Cheers

Rob
 
Hi Rob

Sorry to here of the passing of the relations ,,,,,,,, yep there never seems to be enough time to get on with all the things we want to do :(

I was just going to pretension the chain ,,,,, no a justmet and probably use a duplex roller chain ,,,,,,as this works well with no problems . on some drop boxes we have at work running all day at times , so for something that's only going to be used at weekends and when its not raining here ,,,,,,,so that will be twice a year Rof} Rof} under light load ,as long as there is oil in the box it should do fine.
the diff is from a Ford Escort ,transverse gear box as they are small and the crown wheel just un bolts ,so i can replace it with a standard sprocket blank .

Hope you get some time to get back to your build soon Thm:


Regards Rob sent PM
 
I thought Id revive this old thread as its as good a place as any for the updates. And Hi all, its been some time, work has me over a barrel these past couple of years.... no let up in sight..but...I lurk...

My old furnace has seen better days, she has cracks and crumbles in spots of high wear as in the edges etc. It was also designed to run on coke and is now gas fired so it has a large internal volume which must reduce its efficiency and Ive been thinking about an upgrade.

This vid has caught my eye. I would make the base plate in one piece as no purpose is served by the brick construction here. I would also make the upper ring one piece as it may get bumped during crucible ovement and even though its unlikely, I wouldnt like a brick THAT hot to fall on my foot....

The rest is a great idea, allows you to build a unit to any height you like... for those big jobs, or those smal jobs... as small as is possibole is teh most efficient way to go....

My only concern as this design lacks the outter insulating blanket, how much is the efficiency lowered because of this? Still have to be better than my current beasty... which you can (just) hold your hand against when its fully to temp... amazing...

[ame]http://http://www.youtube.com/watch?v=VA9MLQJM3u0&feature=related[/ame]

The Ole Girl... (showing off.. shes freshly converted here, exploring her abilities)


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