It amazes me that the foam flashes to gas and evacuates fast enough to get out of the way to yield an excellent casting. You do excellent work!

Your craftsman skills are off the charts. Glad I came across your channel.

I don't comment offten but I felt compelled to say that this has to be the most badass thing I've seen. keep it up because I want to see more.

@casthc6795

2 жыл бұрын

hi, do you have any lost foam question

Incredible skills! Thank you, you’ve inspired me to have ago myself!

Incredible work! It shows how organized your mind is, to be able to see the steps necessary to make this complex pattern. I applaud your skills for making it in pieces with foam. Truly inspiring what you do!

Bro, your foam work is a thing of art! Much less what you’ve gone on to do with it! I’m astounded!

Damn, that pattern making is masterful!

Amazing! I study Industrial Design and learned modelmaking and prototyping with foam there, but I had never heard of lost foam casting before I saw this video. Definitely an inspiration for future projects!

@kellycoffield533

2 жыл бұрын

You should take in parts 2,3, & 4 of the same title. Best, Kelly

WOW! You certainly described a complex system easily. I especially liked the step by step you did with the pie cuts from the dish pattern.

Amazing Kelly! Real craftsman and well presented!

I wondered how you got the foam pattern, nice job showing the process of making it.

That is an awesome video. Really great

What a beautiful job!!! Congratulations from France.

that is extremely impressive

That's incredible, I love that intake! I want one.

@kellycoffield533

2 жыл бұрын

Thanks Kurt. I'm pleased with the result.....of the second try in part 3 :-). Best, Kelly

Incredible. Thanks so much for sharing your work.

Stunning work!

Sir, you have the skills to cast your own cylinder heads and I really wish you would, I'd love to see how the water jacket is done in lost foam.

@kellycoffield533

3 жыл бұрын

3 or 4 years ago I did a crude mock model engine block with water jacket just for demonstration purposes, That thread is here. forums.thehomefoundry.org/index.php?threads/unsupported-closed-loose-sand-coring-in-lost-foam.12/ You will need to join the forum to see full size pictures. Best, Kelly

@johnparrish9215

2 жыл бұрын

@@kellycoffield533 Outstanding Thanks

@domenicomonteleone3055

2 жыл бұрын

@@kellycoffield533 I have a question to ask you how hard is it to get started in making Castings this is my question to you from 🇨🇦 #YSW I follow you 💯 from

@kellycoffield533

2 жыл бұрын

@@domenicomonteleone3055 That's pretty hard to answer not knowing what type of skills and equipment you may have. Most people with some basic skills can make a foundry furnace and burner in a weekend or two for $100 worth of materials. You can make a propane burner for $15 worth of pipe fittings then buy a higher pressure regulator and hose for $60. If you have basic woodworking skills you can make foam patterns. If you can put sand in a bucket you can make a mold for the foam pattern. Your best bet would be to join www.TheHomeFoundry.org and view all the examples of people that have done the same and gage for yourself. Best, Kelly

@domenicomonteleone3055

2 жыл бұрын

@@kellycoffield533 i have to see what you where talking about this work does take alot of work and time and if the work in the beginning is not done correctly it will show kelly Thank you kindly for responding back to me in 🇨🇦 #YSW a very big respect back to you

Nice informative video, cant wait to see the rest!

Great info again.. That's impressive work. very inspiring. cheers

Love it. Excellent work

Nice work brother

Великий Мастер! Я многому научился у тебя! Здоровья и долгих лет жизни!

@kellycoffield533

5 ай бұрын

Спасибо, мой друг, Best, Kelly

Very cool and complex project! Looking forward to seeing the pour. There is one moment (just before the refractory coating appears) where the sound is suddenly much clearer - can you make it like that all the time?

@kellycoffield533

3 жыл бұрын

Working on it. I used to think it occurred when I looked/spoke at the phone but I'm going to get a wireless mic and hopefully that will give me consistent audio on the fly. Best, K

You have some skills I wish I had so I’m watching your videos. I’ve got a little Chevy v-6 from an s-10 I want to convert for my old keep. Should be fun! The one thing I needed to know was where did you get your foam?

Hello Kelly, excellent work! Is there a reason you chose to use low density foam for the gates and runners? Thank you so much for making this video!

@kellycoffield533

2 жыл бұрын

The lower density foam absorbs less heat/energy from the melt, so in theory would enable lower pouring temps. It also evaporates more quickly, and in my mind, I envision the runner system filling more rapidly and being more conducive to effectively feeding the part, but I have not confirmed this. I'd like to put an IR camera on the flask some time. It's not as strong nor does it machine or finish as well as the extruded polystyrene (XPS) Foamular 150, making that a better compromise for pattern material. I have a seeming inexhaustible supply from reclaimed (free) expanded polystyrene (EPS) packaging but most of it still ends up in the bin. It has the unintended benefit of visually distinguishing feed system from the pattern features which may be of some benefit to viewers. Best, Kelly

How do you decide both the size and location of the feed system?

Hello Kelly Thanks for sharing your results it's very impressive, theres something which I have been trying to do as much research for and I think youl appreciate the idea. Possibly if you or anyone else can tell me if this can work then that would be greatly appreciated. Instead.of using and cutting wood to make patterns which you then machine for foam, it would be much easier to make a negative mold using 3d printing and casting suitable foam. The advantage of this is time saved and iteration, it can also allow large volumes to made in a.fairly short period of time as foam doesn't take too long to harden. If you get a chance it would be good to see this idea in practice, or if you know others who have tested this. Looking forward.to your reply.

@kellycoffield533

2 жыл бұрын

The process you describe is roughly the practice used in commercial LF foundries for making patterns except pre-expanded polystryene beads are used and invested into aluminum dies, exposed to steam for further expansion, bonding, and forming copies of the expendable pattern. Unfortunately there are no suitable two-part foams for lost foam castings. Two-part foams such as urethanes and epoxies are thermosets, whereas polystyrene is a thermoplastic. The big difference is when exposed to heat, as they decompose, thermoplastics undergo an extra phase change, turning to liquid before turning to gas. Thermosets for the most part just decompose into ash and gas. That extra phase change is important to LF casting. I don't mold patterns because I'm not interested in making a large quantity of anything. Using the commercial process to mold patterns is a very difficult process to control and IMO, impractical for home gamers and gains you nothing if you don't want to make large quantities. By way of example, I have an AFS book on LF casting that is 250 pages long and >60% of the content is devoted to controlling the pattern materials and pattern molding process. Frankly if you were going to go to the effort make a mold for molding an expendable pattern, why not just use a 3D printed hard pattern to make a conventional (bound sand) mold and copies there of? Though I show hand guided pattern routing of patterns in this video, that's just for example. In other videos I show hot wire techniques for making foam patterns. These days almost exclusively use a CNC router to cut foam patterns which is analogous to 3D printing except subtractive instead of additive, but can use commonly available extruded polystyrene, a proper LF pattern material. Not everyone has CAD/CAM skills so the other techniques are to illustrate complex patterns can still be made at home without. Best, Kelly

@ahmedh2766

2 жыл бұрын

@@kellycoffield533 Kelly thank you very much for your reply and depth, greatly appreciated. Looking forward to your other videos. Have a good weekend.

Nice detail on adding an oval and numbers in the front runner. Any info how you did that?

@kellycoffield533

3 жыл бұрын

I pulled a silicone mold from an embossment and then melted wax in the open face mold to make the wax appliques. I comment on that and show the silicone mold for the part number near the end of my video entitle "Pattern Materials for Lost Foam Casting". Best, K

Really cool stuff. Have you considered a cnc router to make all your foam pieces??

@kellycoffield533

Жыл бұрын

This was the last casting I made with hand guided patterns. Been CNC ever since. Visit my channel. Think I've posted a half dozen casting projects since, starting with the successful cast of this one. Best, Kelly

I canno tell what kind of foam you are using. Care to let us know? With your info, a design in an EAA "flyer and Glider magazine would be easy to modernize.

Just your basic do it your self foundry. Hahaha 🤣 Awesome.

Op você tem links alguma loja que vende essa espuma aí não achei nenhum um lugar. Agradeço

@kellycoffield533

Жыл бұрын

Não tenho certeza no seu país, mas aqui nos EUA eu compro em lojas de materiais de construção. É placa de isolamento de espuma de poliestireno extrudado ......Best Regards, Kelly

What do you use for the fillets between the individual parts after they are glued together? Do you use a wax material?

@kellycoffield533

2 жыл бұрын

It's a wax formulated for lost foam casting that burns/evaporates at the same temp and rate as 1.1 lb/ft3 foam. It's called Master Bond and is available from Freeman Supply. See link below. I use the smallest size, 1/8" radius and apply with a warmed ball fillet tool. www.freemansupply.com/products/specialty-tooling-waxes/wax-fillets-accessories/master-bond-wax-fillet---boxes-24-strip-lengths

@casthc6795

2 жыл бұрын

hi, do you have any lost foam question

What kind of foam is this exactly ? And where can I get it ? Does it come in a 2 part liquid form so I can pour and cast complex shapes ?

@kellycoffield533

2 жыл бұрын

It extruded polystyrene insulation board available in 4x8 sheets at retail home improvement stores. For more details watch this: kzread.info/dash/bejne/hmZ8mreBY7fLkbA.html

Thought you might like this, kzread.info/dash/bejne/mo2kw6mEYsXRaKg.html , the guy uses spray foam, not sure if it's polystyrene but the result seems quite good. Difference in my approach would be to use abs negative mold, any added work to ensure the demolding would be smooth would be carried out. The other problem I'm thinking about like you said is tolerances when controlling the pattern being made.

@kellycoffield533

2 жыл бұрын

I had seen that and a handful of others similar. That is urethane foam. I suppose whether something "works" is just a matter of what you're doing and quality of result you find acceptable. It was years ago that I experimented but like this and the other videos suggesting using urethane foam, based upon my first hand experience and readings I'd suspect the castings were ladin with flaws and defects. If it were truly viable, I guarentee it would be used in commercial practice, and it isn't. I cast machine parts and that quality of result just isn't something that would be on any use to me. I've never quite understood the fascination with casting skulls.......so many examples LoL. As an aside, I've seen all kinds of creative evaporative pattern casting where people have used real bugs, flowers, plant life, you name it, then invested them, burned out the pattern and cleared the cavity of ash, before casting them.....and then there are the guys that pour molten metal down ant holes and dig up the casting. I've tried art work but all my art seems to come out looking like machine parts....😉 Best, Kelly

Kelly, how can I help? I am no expert in casting by any means but I have 20+ years in machning, my own shop, tons of cad and 3d printing experience. I am also a boss fan and have a cobra replica I'm building with a Clevland headed 9.2 deck Windsor. Is there something I can offer because I'm very interested in this?

@kellycoffield533

2 жыл бұрын

Hey Phil, contact me through my website contact at www.inlinecarb.com

How much do you allow for shrinkage when making your mold?

@kellycoffield533

3 жыл бұрын

1.3% or .013" per inch....for aluminum

@casthc6795

2 жыл бұрын

hi, do you have any lost foam question

Hello, how are you? How can I get in touch with you and make a quote?

Do you do work for people

have you ever thought about learning 3D CAD so that you could create this in a computer instead and literally just 3D print it into plastic, and then use that 3D printed plastic intake manifold to do the "lost PLA" casting method (by putting the 3D printed plastic intake manifold in plaster, and then burn/melt out the PLA in order to have a perfect part for filling with molten aluminum?.... Plus, you could do this, over and over and over, easily, without having to hand build a lost foam model each and every time. (just a suggestion)

@kellycoffield533

2 жыл бұрын

Make sure to watch Parts 2-4 in this series but as far as your questions, I use a CNC Router to make all my foam patterns these days as in the air filter assemblies in Part 4 of this series, but not everyone has CAD/CAM skills and such software and equipment. Part of the reason for my videos is to show those folks that with modest woodworking skills, equipment, and some patience, complex patterns and professional looking castings can be made at home using the lost foam method. As far as 3D printing patterns, I get this comment a lot: “You should be using lost PLA or lost wax for that”. My reply is: Uhhmmm, IMO, no not so. I like lost PLA and wax for small parts like jewelry and ornamental art work but would never choose it for a part like this. You’d probably need to have used both methods to understand why, but here are the primary reasons. This part is 24”x12”x5” not including gating. 99% of hobbyist would have to print it in multiple pieces and assemble the pattern. It would literally take days of printing time and IMO, the patterns look terrible unless you invested the time to solvent polish or sand out the print lines. The sand mold and flask for this part is 16” in diameter and 40” tall. It weighs 450lbs. Can you imagine the cost of 450lbs of block investment or ceramic shell Probably about ~$1/lb, less if you are experienced with plaster home brew investments but you still need to mix it, incur the labor to apply it, and having to handle and bake that large 450lb mold. A block investment mold that size would take over week to bake out and you’d need a very large oven. For lost foam I don’t need any of that. I just vibratory pack loose sand around the pattern, ladling it into the flask 5-10 lbs per scoop until it’s full, typically taking 10-15 minutes. The cost of the lost foam mold is basically nothing since you can reuse the sand but at retail stores it's 10c/lb, and in bulk $20/ton. Then of course to demold the casting, for investment or shell, you’d have to break and chip away 450lbs of mold media. For lost foam, I just dump the mold on the ground to demold, grab the casting, cool it in water and then blow the refractory coating off with compressed air and reuse the sand instead of chipping away and disposing of hundreds of dollars’ worth of spent block investment or shell......Lost PLA for this part? - No thanks. Best, Kelly

@ooosoo8727

2 жыл бұрын

@@kellycoffield533 hey, that's actually an excellent point; I didn't think about it in terms of the absolutely extreme amount of material involved here in creating such a massive object. You're right, it's even more "cost effective" to do it your way. And that rig that you created in order to pour so much molten aluminum, literally all by yourself; that, is literally genius. That is really extremely impressive that you were able to literally "recreate" a Ford V8's intake manifold, in actual aluminum, at your home, and it works perfect; that's unbelievably impressive!

I worked for a pattern shop and know what kind of work and hours goes into them. how on earth do they justify the cost of you making this for one part that would usually cost $200?

@kellycoffield533

2 жыл бұрын

Hopefully you know more about pattern making than the value of vintage and custom automotive parts.

@blue03r6

2 жыл бұрын

@@kellycoffield533 was this something that was original to the car and makes is more valuable? all I know is, patterns aren't cheap to have made. we made one for summit racing before. the shrink of the mold changed the intake port sizes they wanted so it had to be done several attempts to get it right. and i think they also had problems getting the cores out due to not enough draft. but that's on their engineer dept. not us. what you made isn't easy to do. thats what I know for sure. just seems like it was more of a love than money thing.

Whatever You did there, at @17.19 - do it more often!

Please buy a good microphone