40 years ago I tried to cast an intake manifold. I never finished but i did use the lost foam method. The technology of today looks to have much morepromising resnults. Thanks and you have earned another subscription.

Every now and then I think I want to try this because you make it look so easy and then as I watch your videos I notice your bespoke foundry, and crucible holder, and mold container, etc., and I realize I couldn’t get my foam to look anywhere near as nice as yours. You really are making art. This is amazing.

@kellycoffield533

Жыл бұрын

I'm a fabricator and like to make machinery. The foundry equipment can be done much more simply......don't let that stop you. Larger castings requirer large equipment and the price of admission goes up rapidly as far as effort goes. Small castings that will fit in a 5 gallon bucket are much easier to manage with all aspects of the process. It's true that the castings will never be better than the patterns but working foam is something you can learn and can be done with hand and woodworking tools. It was recent that I started CNC'ing patterns. I have videos on other pattern methods and have made some very complex patterns with those methods. You'll want to get some experience casting simple parts before you pour metal on a pattern in which you've invested hours, but one of the primary themes of my videos is it can be done by the hobbyst in there home shop environment. Best, Kelly

Great job of explaining all the different tasks from 2d to 3d to mold pouring and machining, Outstanding job!

The first time I saw the inline Autolite carb on the Cross Boss 302 I thought how cool. 53 years later the feeling is twice as good!

You have a become a true master of this Kelly. Brilliant workmanship. Bet your customer was really satisfied.

@kellycoffield533

Жыл бұрын

Thanks RotarySMP. Wish I had your CNC and mchining skills. The owner to-be likes it so far but is actually getting a complete turnkey system from me, so more work to do on that. Watch for the follow up video on the completed system. Best, Kelly

@RotarySMP

Жыл бұрын

@@kellycoffield533 I am looking forward to that video. Cheers; Mark

Hello from Australia. I recently found your channel and have been inspired to try casting myself. Thank you so much for the detailed knowledge you have passed on to us.

@leadfoot8593

Жыл бұрын

Hobby casting is huge in Australia!

You are casting treasures for future generations to enjoy. That, and you're sharing the process with those of us who will likely never be able to do this for ourselves. Excellent work👍

I love this channel, metal casting and hot rods, two of my favorite things at one time.

Some amazing workmanship going on there.

Incredible work

I need this intake and the air cleaners in my life 😩😍

I did my first lost foam casting with drywall mud and I'm sold. Every little detail of the foam was on the aluminum. I'm currently waiting for a cnc router to show up from Canada. You do amazing work.

@kellycoffield533

Жыл бұрын

The skies the limit when you can rapidly and accurately make patterns. Best, Kelly

@kennethlang5669

Жыл бұрын

What CNC router system do you use?

@jeremycrisp4488

Жыл бұрын

@@kennethlang5669 I don't have one yet. I finally got the chance to order a longmill and I just finished week one of the estimated 4 week lead time. I shaped my xtruded foam with band saws and routers.

@kellycoffield533

Жыл бұрын

@@kennethlang5669 MillRight MegaVee XL

Fantastic work! I would love to have something like this for one of my Studebaker V8s.

I’m working on making intake manifolds to mount two V692 Detroit blowers on a 702 in.³ GMC V12. Your techniques are fascinating and your videos very informative thank you!

@kellycoffield533

Жыл бұрын

I like all engines and motorsport. That powerplant sounds like a beast. Good luck with it. Best, Kelly

These videos are always a treat, thank you for sharing.

Hey Kelly. Great information as always. Thanks for taking the time to share your experience. All the Best for 2023 🙂👍

You sir are on another level!

Fantastic work Kelly

As always, just WOW!

love your pouring mechanism!

Nice planning and execution, sweet intake.

Awesome stuff Kelly. So glad that I finally got the time to watch your video. If you get a chance, I'd appreciate you taking a little time to talk about heat treatment. Many thanks for sharing what you are doing. Regards Greg

@kellycoffield533

Жыл бұрын

First remark would be you must know your alloy or your probably just wasting your time. Not all alloys are heat treatable, and those that are have specific schedules. I use A356. It's not a particularly high strength alloy but a good all around casting alloy. I rarely attempt higher than T5 condition because in the hobby/home environment the strength gains are just not worth the risk of casting damage due to localized melting or warpage. T6 or better requires tight control since you are so close to melt temp and this can be difficult in kilns and crude ovens. Even so, casting distortion is a risk and may require fixturing. T5 on the other hand is done at much lower temps with little to no casting risk, and achieves a high percentage of the improvement in machinability and mechanical properties as T6. Published schedules will vary nut most will be in 450F range for 7-9 hrs. Cool down does not need to be controlled. It can even be done in a household oven if it doesn't cause divorce. I've even seen people use toaster ovens for small castings. When my wife said the membrane panel button for her favorite function no longer worked on her toaster oven, I told her she better get a new one. The old one lives in my shop now 🙂Best, Kelly

looks incredible!

I was on the edge of my seat. A properly good job mate. Respect.

Glad to see some new videos coming out, I was getting worried you had bailed. Incredible work, and I've learned a tremendous amount from your work. I'd be interested in more on your journey into CAD and CNC if you're looking for subject matter. Thanks for sharing your hard-won experience with us.

@kellycoffield533

Жыл бұрын

I use Alibre Design Pro for CAD and CamBam for CAM. I know a lot more about lost foam casting than I do about CAM and even less so with CAD, but enough to do most of what I need and learn the rest as projects dictate. CamBam is a great value for a CNC hobbyst. Being a casual CAD user, I thought Alibre was comparable to most other paramteric solid modeling software and the being able to own the license without perpetual annual costs was attaractive. On CAM, I design for 2.5D machining where I can and 3D where that won't do. Beyond that, if I did a video on CAD/CAM, by the second minute I'd be telling you more than I know ;-). Best, Kelly

@mrokus7116

Жыл бұрын

@@kellycoffield533 That perspective was actually what I was talking about. There are plenty of good tutorials on the specific CAD platforms, I was more interested in the learning process. I came from a world of traditional CAD and it has been a journey to make the switch to parametric. I was envisioning a look at the challenges of jumping into it. Many are in the same boat of needing to get some CAD skills to be able to make the things we envision. Seeing your challenges and your approach would be interesting. Thanks.

Fantastic work !

Oh man another truly awesome looking part, better than factory I would say! Nice detailed video and great editing! And best of all no nonsense music. Thank you sir!

That was exquisite 👌 I enjoyed watching your videos

A true master job all tips and tricks sometimes is a big secrets but you show us it 👍

Well done Kelly , looks great

I always look forward to your videos😊

great job... thanks for show us your work

good job always interesting to see your process and rig.

Fantastic!!!

Caralho!!!!! O teu trabalho é incrível!

@kellycoffield533

4 ай бұрын

Grazas

Wow! I’m subscribed to a number of casting channels and having found yours, I’m blown away by the quality of your work achieved at home. I’ve just started in home-casting automotive parts using CAD and lost foam. Could I ask if you factor in shrinkage into your designs or if you make your patterns to finished size? It’s the one area of casting that seems to be rarely covered so any tips in this respect would be very welcome. It seems to be something of a dark art and I’m not sure whether to apply a general scaling to my CAD models or whether to try and assess individual features. Examples for me are intake manifolds and transmission bellhousings in aluminum. Thank you.

@kellycoffield533

Жыл бұрын

Aluminum shrinkage is 1.3%. After your design is complete, just scale your CAD model to 101.3% and you'll have accurately sized castings. Best, Kelly

@gasketnineninenine8922

Жыл бұрын

@@kellycoffield533 thank you very much! Such a simple solution.

Love watching your videos. What if you had telescopic tubing of some kind welded to your winch bracket with the cable running inside, that may help with pouring and stability. I know easier said than done, just a thought. Keep up the amazing work !!

@kellycoffield533

Жыл бұрын

I some instances, having the extra degree of freedom the cable affords you is helpful for precision positioning but at some point I overcome the rolling friction on the crane trolley and that can surprise you like someone bumping your elbow when your pouring them a beer from a pitcher or th eice sloshing in your glass. The pivot point is also lower than ideal on the crucible so small changes in angle can make big changes in the pouring rate, but I wanted a sure grip on that A60 because it's a beast. I just don't use that set up as often. Once you're in practice, it's no biggie. Best, Kelly

wow, that looks great, what cad program did you use if you don't mind me asking, thanks

I really enjoy your videos and workmanship. I’m curious how you design the runners? Do you mock a solid piece then hollow them out? I’m trying to build an adapter for BMW ITBs on an LS based engine.

@kellycoffield533

Жыл бұрын

Well, these days I use a CAD function which in my software is call lofting. I define a cross section at the starting position, ending position, and a centerline for it to follow. The loft function morphs one cross section to the other along the centerline. Then there is a function called shell which creates another surface at a commanded wall thickness....in my case .25". Then I import that CAD model into CAM software to create gcode that my CNC router can use to cut the shape. I used to use a manual pattern guided router process, but the CAD process is far superior in every way. The CAD/CAM learning curve can be steep depending upon your backgrond but once I succeeded in lost foam casting a manifold, I was enthusiastically motivated to learn so I could make better parts. Best, Kelly

It's probably going to require a vacuum pump and vacuum reservoir ! A intake like that isn't really designed for street use anyway! Longer runners make more TQ, the intake is probably going to want about 4-5k RPM before it wants to run decent! Depending on the cam and compress, it's going to be 3500+ anyway add about 12" to it and it will start to make a good street able intake, it would be cool on a flat plane crank engine!!

@kellycoffield533

Жыл бұрын

It's all about the cam. Always is. No performance cam I would run on any induction system would run well at low rpm. You're kidding yourself if you think IR can't run strong on a street engine. I've tuned and driven many. Don't need 12" more of runner length. The intake valve to carb booster runner length is already longer than the shortest runner on an conventional open plenum 4brl intake. Vacuum is another matter, especially on an IR system. If I had vacuum accessories,I agree, I'd run a pump and plenum. Told this fella the same. He'll have to learn that himself. Best, Kelly

Always cool to see these come out. Hate to ask, but what does something like this cost? As a one off it can’t be cheap. But as a bespoke signed piece I can see the value. Blower manifolds for Cleveland’s are rare these days. Making me think, hmmmm a custom one off for my project car.

Could i have link of the video where you explain how you made your founry and cnc router please

Very nice job.But was wondering how much power does your furnace use compared to lp gas?Cheaper maybe?

@kellycoffield533

Жыл бұрын

My small furnace is 8kw. It's essentially a kiln purpose built for melting metal in crucibles of a certain size. It can melt 10lb of aluminum from a cold start in 30 minutes. I pay 8 cents US per kw-hr, so about 32 cents. The furnace in this video is larger and was built to be natural gas fired, but I made and use an 8kw electric insert for it for melting and heat treating. About 4x that for this project so $1.28 (and 4x melt time)......inexpensive and I don't have to mess with fuel or fuel strage, and it produces an excellent furnace atmosphere for melting aluminum. Not as fast a some fuel fired furnaces but I turn it on, mold the part, and do other things until it's ready to pour....fast enough for me. Best, Kelly

Great video! Is there a formula you use to calculate for shrinkage, so you can make different parts without "trial and error"?

@kellycoffield533

Жыл бұрын

I increase the scale by 1.3% with the click of a button. that's .013in/in, .013mm/mm, etc. Best, Kelly

@m73m95

Жыл бұрын

@@kellycoffield533 excellent, thank you!

How many degrees above the melting point of the alloy do you pour your metal?

Dear Kelly, The green stuf you dip it in... does that burn away?Or does it become a shell you have to remove later?

@85rocco

Жыл бұрын

He talks about that coating, in detail, in one of his other videos titled, "Refractory Coatings for Lost Foam Casting Patterns" Anyways, Kelly, brilliant as always. Thanks for sharing.

Have you build your equipment by yourself?

@Kelly Coffield - Do you happen to know if molten aluminum will attack steel or iron, like molten tin/lead will attack copper with prolonged exposure? If so, do the respective alloys matter?

@kellycoffield533

Жыл бұрын

Yes, molten Aluminum slowly dissolves steel, and steel is soluble in aluminum. It's not a useful alloying metal with aluminum, in most cases it's consdered a tramp metal, and above small amounts has undesirable affects on mechanical properties. Iron seems to do slightly better but probably only because it develpops an oxide layer that is only slightly more resistant. Stainless Steel is no better and in some cases may be worse. Foundries use ladle liners and refractory washes on metal contact tools to prevent contamination of the melt and prolong the life of the tool. Best, Kelly

Can you recommend the slurry you are using as well as whatever coating is going on the outside? It appears from the video as if you do a single coat of slurry and coating, and then without burning out the foam, submerse in sand and then pour into the shell. Is this correct?

@kellycoffield533

Жыл бұрын

Yes, if you search my channel there is a video dedicated to the subject of coatings. And yes, in lost foam, the pattern is simply placed in unbound sand and then vibrated as the flask is filled to compact the sand to a psuedo-bound state. Then the molten metal evaporates the pattern as it is poured. The gas from the evaporated pattern escapes through the coating into the mold media (dry sand)......no intermediate burn out step is required. The full process is shown and discussed in many of my other casting videos. I built all of my own equipment. Best, Kelly

@elliotcarter3016

Жыл бұрын

@@kellycoffield533 Thank you for the detailed reply! I found your coating video after I wrote my comment. Your videos are an inspiration and I did my first copper ingot pour yesterday because of them.

Trying to figure out what you use for glue to glue up the foam board. Got any details on what you are using?

@kellycoffield533

Жыл бұрын

Discussed in this video. kzread.info/dash/bejne/hmZ8mreBY7fLkbA.html If you sub to my channel there are other vids that may be helpful. The ones from the last 2-3 years are best. Best, Kelly

@noneofabove5586

14 күн бұрын

Thanks, I had the same questions.

Kelly, why are you so into the inline autolight carbs?

@kellycoffield533

Жыл бұрын

I'm really more into 335 series Ford engines. The Inline Carbs were developed for racing programs associated with that engine platform. They were just a novelty that I started with 35 years ago and collected and traded for over the years and then when eBay came along the collectors drove the prices up and they have become quite sought after and valuable. I like motorsport, building engines and interesting inductions systems. People seek me out to build working systems for them. It's fun! Visit my website www.Inlinecarb.com I haven't done much with the site for 10-15 years. I'd rather spend my time building induction systems than websites. Best, Kelly

@kennethlang5669

Жыл бұрын

@@kellycoffield533 what's a 335 series?

@kellycoffield533

Жыл бұрын

@@kennethlang5669 A Ford engine family known for their high flow canted valve heads such as Boss 302/351 and Cleveland performance engines. Best, Kelly

What is the purpose of the coating dip?

@kellycoffield533

28 күн бұрын

It regulates the rate at which vaporized foam escapes to the surrounding mold and improves the surface finish of the casting. Best, Kelly