First time I ever saw a foundry that neat and clean. The neatness is also reflected in the quality of the work.

I did sand casting once about 40 years ago. Amazed you can sand cast such thin fins and gaps without the molten metal disturbing the sand.. I'll have to go look at your other vids to see what magic you are working.

@grinchyface

2 жыл бұрын

The refractory paint helps! It forms a hard shell. I've done some very intricate platinum and stainless castings that occur almost entirely in a refractory dip and the sand is just there for extra support and mass so you can have some control over thermals

@ColinWatters

2 жыл бұрын

@@grinchyface Ah that makes sense.

@RC-fp1tl

Жыл бұрын

@@grinchyface What type of refractory paint, and where can I get some? 😁 It sounds really useful!

@user-qy9rg3nt2l

Жыл бұрын

@@RC-fp1tl kzread.info/dash/bejne/fpibqc2qps6bncY.html

@Juiceboxer0

Жыл бұрын

I didnt believe it's just lost foam in dry sand as well. He coats the foam in something similair to ceramic shell casting

The foundry I worked in never had sunshine, fresh air, birds singing, clean work surfaces or snow! Beautiful castings and clever technique, well done!

@TheDandyMann

Жыл бұрын

Man that sounds like a drag, how did you cope with it? 😉

@paulnadalin2494

Жыл бұрын

@@TheDandyMann Family business! I used to help out when they were busy or short on staff. Usually 1-4 weeks at a time. It was primitive, dark with smoke and fumes. Just like the Industrial Revolution times but I learned basic foundry technique.

That is the neatest little furnace I've seen yet!

I'm a machinist, but am working with pattern makers. Seeing how others do this stuff makes a lot of this coherent when they give me instructions. Thank you and Merry Christmas

Just as they say in medicine, that is art and science. I marvel at your abilities, sir. Nice work.

I am so glad to be sharing this country with people like you! Thanks so much for all you do!

Dangerously inspirational! I may give this method a go at some point, your results are great 👍 The surface finish on the large piece looks really good in the video. Thanks for sharing

I'm very impressed at how well that came out.

Well, that was an understated masterclass. Great work!

Magnificent! So fortunate to discover your great content. The kind of man I think we'd all be proud to call a friend. Genuine, intelligent, resourceful, motivated, intrigued by the man wonders in life, an explorer, a gifted talent and a friendly, humble person all around. Maker-builder friends are the best! Keep up the great, exploratory works!!

Those turned out beautiful, Mr. Coffield.

ive been smelting and casting the last year and a half, and i thought i had seen it all on youtube, but i got so many good ideas on just this one video! your set up and the results are stunning. i absolutely cant wait to watch some more!

Brilliant work....thanks for putting this up..Such a nice way to go before full pattern making and split line madness..

This is incredibly precise! I’m just getting into casting (beginning to make my own furnace) and although I’m veering towards lost wax, I’m finding all of your videos to be fascinating and very informative. Thank you for sharing your work 👍😊

Wow ! This is Totally Amazing! 1. That you are doing it in a Home Shop & 2. That you can do such Perfect Patterns & Casts! Great work & thanks for showing us your process!!

This is my favorite method of casting, less messy and easier to get right. Nice dry loose sand, done.

Thanks for putting up this one, very interesting. This is a little information that I hope you will find helpful. In order for cooling fins to operate effectively they need to have a taper from the base to the tip and the shape of the tip and base (and the angle of taper to a lesser extent) are quite critical. There are a number of excellent research papers available online which describe the dynamics of heat risers / dams in cooling fins. In short - heat will not travel up the fin and dissipate at the tip in a flow (not dissimilar to a stream flowing ) and transfer to the air stream without the appropriate taper. The second issue is that of harmonic vibration. Everything vibrates and more especially in an internal combustion engine in operation there is considerable vibration. Parallel fins without taper will break off sooner or later. I found this out the hard way and before I became aware of the complexity of cooling fins. Keep at it, I've subscribed to your channel and look forward to more of your foam casting videos.

They came out really well, excellent work !

@kellycoffield533

2 жыл бұрын

Thank you Andreas. Best, K

Mr. Coffield, when it comes to this work you are a true artist. The video content and your results are a benchmark. Thank you for sharing your expertise.

@kellycoffield533

2 жыл бұрын

That's very kind of you to say. Glad you enjoyed the video. Best, K

That's really awesome man! The results are amazing. Thanks for posting this.

what a superb work and technique, thank you for sharing !

I just discovered this channel and i instantly subscribed, amazing work. I'd love to see a "working" one cylinder engine made with that big cylinder.

Absolutely facinating work! Your foundry is one hell of a machine also. Subbed!

That is amazing quality you managed to achieve.

Thank you for sharing,very nice parts and great foundry tech! Congratulations!!

I’m amazed the loose sand maintains the pattern as the foam vaporizes. Great, great video. Mad skills.

@darkshadowsx5949

2 жыл бұрын

it does have a thin shell around the part to help maintain surface finish and form. 6:50 "dipped in refractory slurry" so basically a plaster coating.

awesome video. please don't stop making videos and sharing your knowledge

Fantastic video. I’m going to have to watch many of your other videos now.

Really appreciate your methodical approach. Subscribed!

Wow your work and set up are incredible! I am a craftsmen as well and you have impressive skills and your process. Very very well done.

Incredible methods and results. And finally, someone talking about head pressure in casting molds. Alot of guys don't understand the importance of this.

That's some fine work you did there.

That's an AMAZING result man! Excellent job--and a great video. Thanks for making it!

@kellycoffield533

2 жыл бұрын

Glad you liked it!

This is the information I have been looking for. Thanks for sharing. If you read this I am a welder and knife maker as well as just learning how to build all sorts of stuff myself. I might be open to some labor swapping down the road if you have any interest.

gorgeous castings

WOW I was just scanning trough my channels and this came up? I have so many questions but will go back and watch some of your old posts.

@kellycoffield533

2 жыл бұрын

If you are really interested in casting at home you should join www.TheHomeFoundry.org.

I am really impressed with your foundry setup. You did a great job on the castings. I just subscribed.

@kellycoffield533

2 жыл бұрын

Thanks Bruce. I built the furnace first and then added equipment for additional capability, ease of use, and process refinement over time. 5 years on now. I just built a gantry and hoist for larger pours that can be seen in my automotive intake manifold vid. I'm going to have to stop building equipment....running out of space! Best, Kelly

Beautiful work and I love you Furnace...

@kellycoffield533

2 жыл бұрын

Thank you Preston. Best, K

beautiful work

Id love to see you build a motor for a bicycle like the old boardtrackers! I love this kind of stuff!

That is so cool. You seem to make it look so easy. Subbed.

Absolutely amazing. Although cooling goes down if your fins are too close together. Unless you use active forced air cooling. You can download the charts on it. It's the same way with heat sinks. They have to be a certain distance apart if you're not using a pressure fan. You need good air pressure if you put your fins too close together.

awesome - I just learned about how this lost foam process works - I got the TB engine - Trailblazer Vortec 4200

Amazing work, having been involved with green sand casting since the mid 80s, and giving it away about five years ago, this has rekindled my interest, I still have the furnace and all of the foundry gear, but not the proper stuff for foam casting. Looks like a nice Autumn/winter project coming up.

@kellycoffield533

4 ай бұрын

If you are already versed in handling molten metal and conventional sand casting, you will only be limited by the quality of foam pattern you can fabricate. Lot's of info on that at www.TheHomeFoundry.org Best, Kelly

I’ve never seen anyone get this nice a casting from list foam in unbound sand. Wow.

Super impressive casting skills,thanks for sharing!👌 cheers,from Scotland!🏴󠁧󠁢󠁳󠁣󠁴󠁿

@kellycoffield533

2 жыл бұрын

Thank you! Cheers!

Channel gold right here! Subbed ☺

@kellycoffield533

2 жыл бұрын

Awesome, thank you!

That’s “talent”. Great work. Wish you were my neighbor. Thanks for the video

Nice work, man!!

Looks like some good work

I didn't know that lost foam could work that well. That looks alot easier than traditional green sand impresstion or lost wax. I've done only a little casting, but hope to do alot more some day and this video has made me see that lost foam has alot more potentional than I had thought after seeing others do it in the past.

@researchandbuild1751

2 жыл бұрын

It's def the easiest way to cast for the DIY'er in my opinion. I made some lost foam back in the day and it "just works"

as a former worker in this field in Foundries and Forges, I helped develope, mix, sell, casting binders whith materials, and tooling. "I can see"how new printing tech would take the abilities of Casting Modeling to an Un Known Level! looked CLEAN To ME!

I've done a bit of casting here and there, jewelry mostly, with soft and hard cast lead for bullets getting some time. For intricate parts, I've used the lost wax process with plaster of Paris and greensand or clay for two part molds with durable, removeable plugs. This is the first time I've ever seen someone use dry sand, and without sprues or risers. Since the pour was a complete success, I was thinking I might try it your way. I'll likely have to indulge myself with a few new tools (poor me, lol), but this will add to my enjoyment of life. Thank you.

@kellycoffield533

2 жыл бұрын

You should consider joining www.TheHomeFoundry.org and pwruse the lost foam sub forum. I have many informational and project threads there. Best, Kelly

Wow. Mr. Fancypants here, I've never even seen a heating solution like that. My foundry is home made from an old air compressor tank with 300 lbs of refractory cement, fired by propane. It works, but .. I have a bit of envy.

@kellycoffield533

2 жыл бұрын

300lbs? Wow, I bet that takes some fuel and time to come to temp on the first heat! Best, Kelly

@IBWatchinUrVids

2 жыл бұрын

@@kellycoffield533 Yeah, I use that one for bigger melts, or for ingots. I use a **NEVER DO THIS or the Internet safety police come** ceramics kiln for small stuff. Works fine if you're not an idiot about it.

( surprising to me that this video is by far the most viewed of my videos) not realy it has the word casting cylinder thats why i came over this video alot of people work on old 2 stroke engines and think of an updated cylinder/head Kelly great work by the way 🙂 you make it look so easy

Hats off to you SIR.

Awesome, I had no idea you could cast with loose sand!!!

Excellent video! Thanks!!

Such great content!👍🏻

Really impressed.

Great video! I have been looking for a method to make parts for my ice fishing product. I have been using steel and welding and grinding takes a lot of time. I had some aluminum parts made that were welded together.

@robertlafontaine805

2 жыл бұрын

Sorry about that I pushed the wrong button I didn’t finish. I think making the fan blades pictured in my profile would be the best method.

This is an inrtersting channel,i think i can learn a lot here, thank u sir,thank u for ur great work, sincerely from China

I love it! I want to make some serious Corvair heads with heart shaped chamber and boss style ports. This looks like the solution to me. Green sand appears to rough. I've seen people use vacuum on lost wax castings leaving the top wide open. The vacuum can't pull the metal through the sand or plaster so it just sucks the flue down initially and stays there. It removes gas pockets almost instantly as soon as the vacuum hits. You see the dross forming in the flue instantly retract enough to wrinkle the surface and that's it.

@veeekin9casterman169

2 жыл бұрын

Great Idea ! Many months of hard work may result in a set of heads producing 250hp na from factory short blocks, the objective. Along with all the others into aircooled opposed flat fours and sixes, for the last 60 years, lol. Like my world domination plans, yours includes the canted valve arrangement of the Boss Fords, or semi-hemi, the ports sized for the swept volume of the +2.7L Corvair short blocks. A unique solution to the pushrod angle problems is the secondary pushrod design of the 60's hemi prototypes by GM, so very viable in the Corvair application, and neatly done, allowing 3 and 4 valve variants, heh heh. > A cored watercooling jacket or exhaust valve ' HD loop ' could allow modern turbocharging levels and requisite cooling. A great deal of thought and engineering would have to be exercised for the culmination of 4.2L Corvair Turbo heads, cast, and machined. The lost foam methods demonstrated here is likely the simplest, the cast and coated bigbore cylinders too. Imagination, opportunity and ambition may be sufficient to achieve the necessary desire. ' Simplicity is the highest goal, achievable when you have overcome all difficulties. ' ~ Chopin ' One thing we do know, that we dare not forget, is that better solutions than ours have at times been made by people with much less information than we have. ' ~ Wendell Berry ' Vision without execution is just hallucination. ' ' Whether you think that you can, or that you can't, you are usually right. ' ~ Henry Ford

@billallen4793

2 жыл бұрын

There is a guy in town who said he'd sell his corvair part's pile. And 4 or 5 car's, and 8 to 10 engine's in total for 8500.00 if your interested..from Wyoming USA 🇺🇸 🤠

Kelly that is awesome.

Très intéressant reportage ! Bravo au Fondeur !

super clean job sir, well done :)

That turned out nice!

That is bloody impressive with loose sand.

Looks great!!! perfect work!!!

@kellycoffield533

2 жыл бұрын

Thank you very much!

Hi Kelly, a very interesting video and a very impressive foundry set-up. Good to see you use PPE and a well laid out work area. About the only thing that concerned me was the dumping of the sand on your driveway. I realise that the sand would be warm to hot but it has the potential to pick up some moisture from the cold concrete and judging by the snow bank it was cold. Can I suggest that you pour out your sand in future onto a clean drip tray or similar. It will keep your sand clean and dry and free from any debris that might be on the driveway. That will save having to dry and filter your sand. Apart from that, excellent work and you have got yourself a new subscriber. Mark from Melbourne Australia

@kellycoffield533

2 жыл бұрын

Hi Mark, for the short story, it's such low value media I've found it better to replace it than renew/recycle it. The long story, it's true, the single most important thing other than refractory for LF sand is that it moves under vibration and dryness is important to that. Their byproducts of decomposed polystyrene degrades the sand with repeated use. You can heat the sand to remove these organics but the energy cost to do so is more than the value of the sand ($20/ton in bulk for $5/5 gal bucket retail). I used my first 300lbs of sand for almost 5 years before I replaced it, and I treated it with disregard, except dryness, and the driveway contact didn't seem to be a problem as long as it was not visibly wet. Any fines or organics I may pick up arent a problem for aluminum. I only perform gross filtering through .090" perfortaed plate to remove clumps. That 5yr old sand saw a lot of use was sufficient for all but the most challenging vibratory packing and fresh ne sand does perform better. Also, since the foundry was allowed to dispose of thir sand in landfills, I assume the same for mine. Now if it was higher value media like the commercial ferrous LF operations, they have fluidizing furnaces to recondition/reclaim the high value media. Best, Kelly

Wow, Very impressive..

I wish I had a neighbor like you around. I always had an interest in casting metal and I finally found the time to start building an at home metal foundry. I'm just going to 3d print designs and use those to cast.. I like your method better though. I'm interested in making a little RC engine to learn that's why I thought fins.. It would be cool to have a small motor I made from scratch. I regained my interest because I need to make some small BLDC motor parts for a project and I have my own design I want to build and try.

@kellycoffield533

2 жыл бұрын

For very small finely detailed stuffed you may be better of with printed patterns and investment casting. Though those materials are pricier, the molds and patterns are small so not much material or cost involved. For larger machine parts that's a different story and lost foam certainly has advantages. Best, Kelly

Very great Job !

Wow, amazing results with out having to buy expensive refectory ceramic casting!! I think I'm going to try this with 3D printing and pla

@darkshadowsx5949

2 жыл бұрын

you could make the ceramic refractory mix last a lot longer by using it as a thin shell coating like he did. not sure he used the ceramic variant though. 6:50

Fantastic!! I would love to build a clone of a Harley flatty. Wow you are set up for some big work.

Just found your channel and subscribed. Very nice work

Very good, I'm following in your footsteps, I'm making a pair of Shirts alerted for two Chevrolet jugs 98.48 mm that I'll put in a 1/2 VW with a reinforced case.

Hi Kelly, many thanks for your tutorials! I think those two videos you mention are most visited because they depict a summary of best practices to achieve a goal in quality , rather than focusing on a specific result. On the other hand, please mention the material of pouring cup ; I couldn't understand quite well. Good luck!

@kellycoffield533

Жыл бұрын

Thanks Mihai. The pouring cup is made from moldable ceramic fiber. There is a video about them on my channel. Best, Kelly kzread.info/dash/bejne/f32txrFvaaa0kdI.html

@mihaimastacaneanu8505

Жыл бұрын

@@kellycoffield533 Thanks, I owe you a lot in learning how to do things properly and with reasonable costs!

That’s great, thanks for the video 👍

This is pro level stuff

Thanks for sharing so many details in this video! Can you also tell us what alloy of aluminum you are using, pour temperature, and what heat treatment you would use? Really fascinating!

@kellycoffield533

2 жыл бұрын

A356 Aluminum, 1425F, T5. Best, Kelly

Quite nice dude.

I've used plaster and wax to make jewelry castings. This is very interesting though I had no idea this was actually a thing. Model makers and prop makers should pay particular attention.

very tidy shop, this shows that the performance from top to bottom will be very good, in fact the resulting work is excellent. I am going to go through your video list to see if you have info on what alloy you would recommend for petrol powered cylinder head and heat treatment

@kellycoffield533

2 жыл бұрын

I use A356 for most everything because it's a good all around casting alloy but can and needs post heat treatment for best strength. You might look into AlMag 35 (aluminum alloy 535) as it has good as cast strength and machining properties.

@tomassosaoconnor

2 жыл бұрын

@@kellycoffield533 Would a high percentage copper alloy (like 25% 30% Cu) need heat treatment?

@kellycoffield533

2 жыл бұрын

@@tomassosaoconnor IDK. I don't think I've ever seen an aluminum alloy with that high of Cu content. I suspect it would be very brittle.

Great job, First time I saw casting in sand

The first engines to be mass produced using lost foam were Saturn blocks & cylinder heads. You could actually see the foam patterns in the castings.

@foxman105

2 жыл бұрын

You can still see them in some newer engines. Styrofoam pattern on the inside of the valve covers ect.

@MrWaalkman

2 жыл бұрын

I was going to say the same thing. I worked for Saturn and it was cool to watch a casting being poured by a robot. :)

Восхитительно, работал на художественном литье - алюминий, латунь, работали страмбованными опоками, с моделями из под ЧПУ, из МДФ. И с выплавляемыми восковыми моделями, вы наверное льете , что то типа пенопластовых (полистироловых) моделей? Чудесно организовано, и произведено!

We did sand box casting at school and used inlet and outlet sprues. I wondered if that would improve your experience?

Very interesting, luvd it

do you think maybe cutting a pac-man shaped piece of material to set ontop of the sand opened toward the ceramic cup. to compress the sand some while vibrating

Be careful with those ceramic fibers. Nice work. thats a awesome looking foundry to btw.

You got another subscriber!!

art is it !!! do you think can we have a metallurgical picture of your casting in one video? thank you

Super Impressive 😊

Fico muito bom essa peça

Thank you for this awesome video! I learned a lot. Where do I buy aluminum shot or pellets that are the right alloy for water cooled two stroke engines?

@user-rp4je2gc2o

2 жыл бұрын

I'm interested in this too, could old, used 2 stroke cilinders be re-melted ? I have some damaged ones laying around. However, would you have the chrome or nicasil lined or would you press a cilinder sleeve? I want to make a custom cilinder for my moped to use a yz80 sleeve

@daos3300

2 жыл бұрын

use old engine blocks/cylinder heads, plenty of quality material from bikes and cars available, pretty cheap too.

That's a really awesome furnace setup you've got there! Do you have a video explaining the whole thing? I'm still using my little propane furnace to do my casting, you're in on a different level!

@kellycoffield533

2 жыл бұрын

It's a bit dated but here ya-go. kzread.info/dash/bejne/pKquzad-abGreKg.html Also may want to check this out: forums.thehomefoundry.org/index.php?threads/furnace-cart-and-lift-build.278/page-3#post-9376 Best, Kelly

very interesting process, with great results!!! Like others, I have a couple questions if you dont mind.... How much material do you leave for machining? I.E. How much undersize is the bore so that you can machine the proper diameter? How much extra thickness do you leave for machining the flanges, where the heads and block would mount?

@kellycoffield533

2 жыл бұрын

On the large cylinder .063" would probably be enough but I'd allow .125" machine stock on all surfaces just in case there were some surface imprefectins in the casting. Half that on the small castings. Best, Kelly

could not hear what you used to make it vibrate thank you for your time in this matter

@kellycoffield533

Жыл бұрын

I use a pnuematic turbine vibrator. There are various sizes with different levels of vibration and air usage levels. I use GT25. Search eBay for turbine vibrator and you'll have many hits. Best, Kelly

@cornishman1954

Жыл бұрын

@@kellycoffield533 thank you so very much

@privateprivate1865

Жыл бұрын

@@kellycoffield533 could you use a of center weighted electric motor? Just curious. Also, excellent video ☮️👍

@kellycoffield533

Жыл бұрын

@@privateprivate1865 Yes, off-center/eccentrically weighted electric motor will work. Best, Kelly