Thank you for posting this. It is good to see the original being made by it's inventor. I rank thieves with people who hurt children.

@olfoundryman8418

4 жыл бұрын

Lancer, I guess it boils down to YT being an open place where anyone can put anything up. There were several people who knew of my intention to do a video on box construction and at least a few of them had a pretty good idea of how I was going to do it. Unfortunately I was very slow getting around to it (about 2 years). Not entirely my fault as ill health and surgery got in the way and to a certain extent still is. There is nothing illegal in the usurping of my idea - immoral, unethical - maybe, and definitely not nice but YT is a dog eat dog world, And we have little option but to put up with it or walk away. I note that the two efforts out there that would seem to be based one upon the other and the first upon mine are riven with mistakes - the first is fixable but the second is just plain crazy. When these two came out I nearly abandoned mine thinking that I was too late but then a friend pointed out that mine were better. I like to think he is right but ultimately the viewers will be the judge. Incidentally I can not claim to be then inventor as 45 corners have been round on large boxes for machine moulding lines for a long time. Perhaps though, I can claim the concept on hobby sized boxes having first done it somewhere around 1975. Thank you for your comment... Martin

Thanks for the video Martin, I've learned more from watching your videos than all the rest on KZread. Doing things for quality is always worth the extra effort and money. Many of the hobbyist here try to do things the cheapest and easiest, needless to say their product shows it.

@olfoundryman8418

4 жыл бұрын

Ray, Sadly you are not wrong. Many on YT seem to consider foundry as just a way of melting down any old junk they find lying around and of reclaiming at great expense of fuel totally unsuitable alloys (cans - Grr). All hobbies cost money - look at the cost of a decent camera for example if you wish to get into photography in a respectable way. It is a big bone of contention that foundry people do not always see the truth here, and yes, their product shows it.... Martin

Great to see a craftsman at work

@olfoundryman8418

4 жыл бұрын

Stuart, Thank you for saying so.... Martin

Martin, good to see you again. As always good show sir. Hope all is well with you and yours. Thank you.

@olfoundryman8418

4 жыл бұрын

Donnie, All well thanks for asking - the show must go on 😊… Martin

Mate i cant thank you enough. Last xmas morning i was awoken to my neighbours banging on the front door at 4.30am with your shed is burning. I do woodwork as a hobby, but i was trained as a boilermaker and now teach Woodwork and Metalwork as a high school teacher. Our latest syllabus was updated a couple of years ago and as i had no shed to work in i decided to read the document when i discovered a metal art section, which included modeling, smelting, CAD. So i jumped onto YT and done some searching..... (i think i have watched most of your clips by now) and i found your videos. Anyway this year my year 10 students have developed their skill with fusion 360, and we will be printing their designs out with the 3D printer and then making molds and casting using the techniques you have taught me this year. The way you are passing on your knowledge and expertise is amazing, as part of my metals course my students have to watch your videos so they can explain to me how this will all work, and more than a few have gone on about how cool this stuff is, i personal think they just like melting stuff, but your knowledge is being passed onto the younger generation. Once again many thanks mate.

@olfoundryman8418

2 жыл бұрын

Mark, Bless you for getting people to watch my videos 😊. A warning about 3D prints in that they do not make the best of patterns - the layered structure tends to grab the sand and make clean pattern withdrawal difficult. Prints seem to need a fair bit of painting and sanding to give a good pattern. PLA does not sand well - too gummy. ABS is better but of course harder to print, some playing around with filament types may be a worthwhile exercise. That said the idea of combining a program like fusion - with 3D printing - with moulding and casting is very attractive, particularly at a beginner stage - good luck with it. I suspect that you are right in that many are only interested in "just melting stuff" But its an addictive hobby and some at least will go on to delve deeper and make actual useful things rather than ingots out of melted down junk. Thank you for your most enjoyable comment.... Martin

Martin, I know you know, but still have to say that you are absolutely brilliant and I wish to thank you for that. Stay safe!

@olfoundryman8418

4 жыл бұрын

Anders, Thank you for our comment - staying as safe as we can!.... Martin

Nice job! That's a serious furnace, for serious work.

@donniebrown2896

4 жыл бұрын

Try to go back and watch the Master doing the good stuff. Ever seen an engine piston cast?

@olfoundryman8418

4 жыл бұрын

Mark, Built about 1975 still the original lining thousands of melts, new lid though. It is the middle furnace larger one holds 75 Kg of aluminium... Martin

@olfoundryman8418

4 жыл бұрын

Donnie, don't remind me I still have to do another 4 of those blighters... Martin

That was the fastest "couple of minutes" I've ever seen! ;)

@olfoundryman8418

4 жыл бұрын

Steve, How do you know I did not cut the video - Ok ,Ok so I did not cut the video - I am just an impatient B 😊… Martin

@theflyingfool

4 жыл бұрын

@@olfoundryman8418 LOL!

What a great teacher you are. Thank you.

Another awesome video, thanks Martin.

@olfoundryman8418

4 жыл бұрын

Wikus, Thanks... martin

Thank you and a warm welcome back! Great to see the master back in action!

@olfoundryman8418

4 жыл бұрын

John, Not gone away, just a bit slow these days - more soon.... Martin

Thank you for the video, I am enjoying this series!

@olfoundryman8418

4 жыл бұрын

Jesse, More to come - enjoy... Martin

Me: "That's better than any casting I've made, ever, by far. OldFoundryMan: "I've Made a bit of an ash of it... plenty of room for improvement." I'm off to look up what "exothermic" is. I haven't heard of that before. Thanks very much for the videos.

@olfoundryman8418

8 ай бұрын

Elizabeth, Just curious - do we have a female foundry person? Often a first off is a little rough and only one seeing that first casting do little problems needing to be fixed become apparent that sure was the case here and subsequent castings were better (Mainly!) Oh, and there is always room for improvement - such is the way of foundry. 😊 Re exothermic :- it is added to the top of feeders and its job is to catch fire and generate a lot of heat thus keeping the feeder liquid for longer so it is better able to provide liquid feed metal for the solidifying casting underneath. It is a commercial product made (in this case) by Foseco, it is called Ferrux NF. I use it one most of my castings. The videos are my pleasure..... Martin

@ElizabethGreene

8 ай бұрын

@@olfoundryman8418 Thank you very much for the reply. I'll have to give the exo a try.

great video and info Mr, thanks for sharing!

@olfoundryman8418

4 жыл бұрын

sikamikan, Sharing is my pleasure... Martin

Great job mate!!!!!

@olfoundryman8418

4 жыл бұрын

Thomas, Thanks.... Martin

Thank you very much! A superb demo as usual. Very much appreciated.

@olfoundryman8418

4 жыл бұрын

Wet, Your comment is very much appreciated too... Martin

Jeez you make that look so easy !

@olfoundryman8418

4 жыл бұрын

Ian, Lots of practice - just like playing a guitar, dancing ballet, or gourmet cooking - I don' do any of these. 😊 Enough practice and anyone can become good at anything ,few though can ever truly excel - I don't do that either... Martin

Great content, many thanks for sharing

@olfoundryman8418

4 жыл бұрын

Rupert, Thanks for saying so and its my pleasure... Martin

Nice work Martin. You nailed those deep lugs.

@olfoundryman8418

4 жыл бұрын

Geoff. I have to admit that those lugs worried me from a moulding perspective but they do have 6 degree side slope and that sure helps, being 3D patterns does not though 😏 Wait till you see the lugs on the now modified patterns.. Martin

You would be an asset if you joined the "Home foundry forum". There is a lot of general chat, but somebody with your experience would be amazing! You could even post some of your videos there. I would personally love to see you over there with open discussion.

@olfoundryman8418

4 жыл бұрын

OMM, Over the years I have been asked to join one forum or another and indeed I was once a member of one. I found that as such I was devoting a huge amount of time to the various questions raised. This was time that I did not really have then and certainly do not have now. Worse still, the experience was ultimately not pleasant, and I am sorry but I have resolved not to repeat it..... Martin

@omm7763

4 жыл бұрын

@@olfoundryman8418 that's too bad. You have a lot of talent that will be missed (or other will not benefit from). I fully respect your decision/position. Matt

Thanks again Martin!

@olfoundryman8418

4 жыл бұрын

Jaap, No problems… martin

Jolly good stuff old man staying in is a brilliant idea.

@olfoundryman8418

4 жыл бұрын

Turner, Not much else one can do at the moment - jig saw puzzles are OK but have to take break from them!.... Martin

@timelessengineering

4 жыл бұрын

@@olfoundryman8418 yes games have been the order of most days in my house but I've been lucky enough to give the old Sheraton lathe a well deserved birthday at last.

@olfoundryman8418

4 жыл бұрын

Turner, You prick my conscience - a little (lot) of TLC in my shed would not go astray... Martin

Thank you so much! I love your vids. Stay safe... be well.

@olfoundryman8418

4 жыл бұрын

Darin, Thank you doing our best to stay safe… Martin

I'm happy to see another video from you. That made my day and its 1/4 to midnight.

@olfoundryman8418

4 жыл бұрын

Eleventeen, More coming soon just hang in there.... Martin PS. Try and get some sleep 😀

@eleventeenmachine5991

4 жыл бұрын

@@olfoundryman8418 Excellent. I watch in awe of the quality of the products you make. As well as probably thousands of other people. I haven't been able to do much casting yet. But I'm learning from guys like yourself and a couple others. You are top of the chain. By far the best explanations. I've been taking notes. So once I can get out and make a melt t'll pay off. And as far as sleep goes? Thank you. I get it in bits. It's due to a failed back surgery. The surgery was a success in fusing the vertebra. But the nerve damage was the failure of it. Been over 5 years now I'm used to it. So that's why I watch great youtube videos. Like yours. Anyways thanks again.

@olfoundryman8418

4 жыл бұрын

Eleventeen, Back surgery - you have been reading from my playbook. One disc removed 1970 recovered well. But lost some of my balance about 3 years ago disc in neck impacting spinal column surgery stopped the rot avoiding the wheelchair but did not restore balance (nerve damage as you say) now I have CFS as well. 😰Today I poured 10 castings but totally exhausted myself doing it - will take 3 to 4 days to recover! My advice re back is at all costs keep it moving inactivity makes it worse - use it, but don't push it too far. Get a phisyo to prescribe some back strengthening exercises. Foundry is hardly the occupation for bad backs (believe me I know) but good luck with it. I have a mate who was born in nineteen eleventy eight, your not related to him are you? 😀 Martin

@eleventeenmachine5991

4 жыл бұрын

@@olfoundryman8418 I hope I'm not following any playbook. Well other than what the lord wants of me. Although I don't think he was responsible for my rather long bouncing trip down a short flight of stairs. It bulged the disc in my L5-S1. Which was the first of it. They eventually removed it and fused it with a cage, rods, and screws. Then recently after 4 years I had another surgery to remove the rods and screws. To see if that would cut the pain. Nope. It made things differently worse? That sounds funny. But makes sense. I have pain that runs from the surgery sites down my legs 24/7 365. The severity of which changes from where i can do things for a little while to me not wanting to do anything but lay down on ice. And it goes without saying that I'm eating pills like a spoiled child gets cake. Which is why I'm going to try one last attempt at stopping it and the pain. Going to go for the trial with a electronic nerve stimulator. I've heard and been told to avoid it. But, it's better to have tried than to have not and wondered what it later. I'll try it to get rid of the pills and patches. I have no upper neck issues yet. Thankfully. But I've had knee work done once. So that's not great. But it's better than it was. So I can't complain. Hopefully yours doesn't get worse and yes activity is the key to minimizing the pain. Unless it was activity that caused it. Then it's like you're said a 2/3 day recovery in bed.

G’day Martin. One day I hope to get my castings half as good as yours, they look good from here. I’m enjoying the series, thanks for sharing. Cheers. Peter

@olfoundryman8418

4 жыл бұрын

Peter. You just have to start casting when you are 10 or 12 and kept going until you are (groan) 😱 75 -easy peasy - a good bit of the series to go yet the important stuff is about to start!... Martin

Looks good to me Martin 👍👍

@olfoundryman8418

4 жыл бұрын

Jess, Yeh, it turned out alright. - not unhappy ….. Martin

Thanks for sharing!

@olfoundryman8418

4 жыл бұрын

Craig, My pleasure… Martin

I found using 3D printed patterns got better after 2/3 uses, So I now dust, rub in by hand, brush off and re dust before first use, works better then.

@olfoundryman8418

4 жыл бұрын

Andy, Fortunately I have a tame pattern maker who after sufficient pleading begging and bribery will make me a proper pattern. However I do use 3D patterns but I prefer to do a fair bit of sanding painting etc to get them smooth enough to do my sand justice. What you suggest is interesting and I have a raw 3D pattern in use currently (one of the box sides) and it will be interesting to see how it goes with further use. What do you dust with?.... Martin

@WarGrade

4 жыл бұрын

@@olfoundryman8418 Martin, It depends on what I am making, you have seen the detail my oil bonded can produce, I can easily see print lines from a .2mm layer print.

Sir nice to see you again! But im sorry i see this is part 3 i dont know why i wasnt notified before. I will be finding the other ones to watch. Stay safe and take care

@olfoundryman8418

4 жыл бұрын

Menard, doing our best to stay safe. I think that you will just have to put missing the first 2 down as another mystery of YT... Martin

Good job. I will try to follow your example and get same quality out of my castings. But as it said, you can´t always get what you want, but if you try sometime you find you get what you need.

@olfoundryman8418

4 жыл бұрын

umlooad, It is just a matter of patience practice and perseverance together with a desire to learn to do it righty - with these youwil get what ypou want.... Martin

The castings don't have to be pretty if it is used for work. They just have to be solid enough to be useful. Still, the casting looks good to me. Are you going to use the castings to form a jacket or a flask? If a flask, I suggest that you incorporate a half round dowel on the inside of the flask to keep the sand from slipping out when you are maneuvering either the cope or drag. Or you could modify the 3D file. Keep up the good work!

@olfoundryman8418

4 жыл бұрын

Sand, You are right but I am a bit of a pedant and I do like a good looking casting. However on this occasion the effort to make my fine facing and the lack of any real need for prettiness won out. Flask, but there are already sand retention ridges on the bottom and top of each side. I am surprised that you did not see them. Nothing worse than a drop out just as you go to assembly a finished mould. I do note that some people do not seem to use any sand retention ridges and they seem to get away with it but I suspect that is because petrobond hangs in better - maybe?? I note a lot of people with a narrow grove or just one ridge in the centre of each side - recipe for disaster IMHO...Martin

Martin your experience is showing! What is the difference between facing and backing sand? I'm thinking facing sand is finer so as to improve the finish. Just a guess. Also what is the topping that you put on the exhaust port and what is it's purpose? Thanks Tom

@olfoundryman8418

4 жыл бұрын

Thomas, I make the facing sand from half new (unused) sand and half used sand I pass this mixture through a grinding mill (there is a video on this kzread.info/dash/bejne/fm2lspVyqZarZM4.html ) This does make it quite a bit finer which does improve the finish of the casting. The topping that I put on the top of any feeders is an exothermic called "Ferrux NF". It is made by "Foseco" and its job is to catch fire and generate a lot of heat so the feeder stays liquid longer and is thus better able to provide feed to the solidifying casting underneath.... Martin

@thomascoughlin8026

4 жыл бұрын

@@olfoundryman8418 Thanks Martin

What are you using to measure the temperature of the molten metal? What is the exothermic that you are using on the feeder?

@olfoundryman8418

9 ай бұрын

Gregory, Temperature measurement is via an MIMS type K thermocouple 6 mm diameter, protected from metal attack by a boron nitride wash. The exothermic is "Ferrux NF" made by "Foseco"

I'd love to get a good look at your furnace

@olfoundryman8418

6 ай бұрын

docven, Not really all that much to see! But maybe if I can summon up enough strength (difficult) I might be able to put a shortish video together. I will see what I can do..... Martin

@docvencil2222

6 ай бұрын

@@olfoundryman8418 I like the large size of the furnace and crucibles. Do you run propane or oil in your burner? What is the diameter of your burner hole?

@docvencil2222

6 ай бұрын

Thanks! I want to be able to melt large amounts of metal for large pours using a big ladle@@olfoundryman8418

@olfoundryman8418

6 ай бұрын

Docven, I burn diesel fuel the burner hole is about 1.5 inch but I use a propriety burner designed for oil and a large blower to provide the about 1 psi air.... Martin

@olfoundryman8418

6 ай бұрын

docven, If you are going to use your furnace with a fixed crucible to bale out from via a big ladle you should look to using basin type crucible. These are wider and shallower than the more usual home use style crucible smallish ones of these (50 Kg) can be a bit hard to find but checkout a few crucible manufacturers web sites there should be a catalogue of sizes there. The furnace I used for casting the four barrel throttle bodies (see video) was fitted with a basin type crucible that held 75 Kg of aluminium..... Martin

You've got your license plate in the video m8. May not be desirable.

@olfoundryman8418

4 жыл бұрын

John, I am hoping some rich dude will pay me a fortune for it! So far no luck but its only been 52 years! 😏. You make a fair point though, perhaps I should cove it up....Martin

Thank you for yet another instructive video. I am starting out on this journey and if I could produce the sort of result you seem barely satisfied with I would whoop with joy. But I am getting there. A number of questions: What flux (if any) do you use in your aluminium? It seems your furnace is diesel fueled? It would be nice to have some explanation one day. Also you promised details of your sand conditioner, please do share that. When you cast, you put 'exothermic' on the feeder, what is that? Thanks for sharing your immense knowledge and experience, I wish I could sign up fr an apprenticeship.

@olfoundryman8418

4 жыл бұрын

Coen, Producing the sort of result I get is just a mater of practice and a constant effort to improve. The flux I use is "coverall 11" it is made by "Foseco" and is what is called a "drossing off" flux. My furnace is indeed diesel fuelled I use a commercially built burner that I bought new (at great expense 😊 ) many years ago - oil burners from home heating furnaces can work well. There is a video on my sand conditioner see here kzread.info/dash/bejne/c4eIr86whczSZbw.html . The exothermic that I put on the top of the feeders is called "Feedex NF" it too is made by "Foseco" its job is to catch fire and generate a lot of heat which helps to keep the feeder liquid for longer so it is better able to feed the casting underneath. I do indeed badly need an apprentice..😊...Martin

@bobhorn5867

Жыл бұрын

Coen...As I watched this video I had the exact same questions. I'm a newbie as well. What flux and how much? Exothermic and how much? And for me, is that a thermocouple you're using for temp and I assume you're reading in C and not F? Where would one get that? Thanks Martin!

It’s looking good to me! I hope you are being safe and I’m wondering if the folks in Australia are holding all the toilet paper like they are here? Of all the things to hoard!

@olfoundryman8418

4 жыл бұрын

Rocking .All safe .Toilet paper? What toilet paper? Would you believe the shops sold a years supply of toilet paper in 3 weeks! I have absolutely no idea where it all went - we did not run out but it got close. Rice pasta flour sugar frozen foods meat and vegie tinned foods and fresh meat also ran out - got a bit grim for a few days some people must have freezers and spare rooms full of stuff - hope the power gors off and they loose it all!... Martin

@olfoundryman8418

4 жыл бұрын

Lorna, Yep, I loved it - 4000 rolls that would fil a house!. A middle digit well deserved 😊… Martin PS, maybe all the foundrymen are smelting metal over great pits of burning toilet paper..

I smiled when you said you're using a " small crucible" A8 . that would be quite large for me Martin, my range is A4 to A12 & I only have ring shanks & lift out tongs & have never needed any unesessary "clips" to hold the crucible in as you say I've never lever dropped a crucible & thank you for sending me the molding box info.is your furnace oil fired or gas? Graham.

@raydirkin9107

4 жыл бұрын

I'm not 100% sure but seems like I remember him saying he burns diesel fuel.

@olfoundryman8418

4 жыл бұрын

Ray, Spot on, diesel it is... Martin

@headstocktailstock

4 жыл бұрын

@@olfoundryman8418 I'm still on coke [no not that stuff!!] but when we pulled the father in laws house next door down I "inherited"a large tank of diesel & the central heating burner so I might rig it up.save messing on with coke.

@olfoundryman8418

4 жыл бұрын

Graham, Hey baby way to go snort snort damn this Hollywood cold! Seriously though central heating burners work well. I have two that I have used and a local foundry has used a largish one to melt his bronze for years. They are nice self contained units blower oil pump and electric start in one neat little unit only problem is that they are either on or off - you can not turn them up and down. You can though get a range of jets for them, rated in gallons of fuel per hour. Much easier than coke something less to have to worry about.... Martin

@headstocktailstock

4 жыл бұрын

@@olfoundryman8418 That's fantastic info Martin, I've a commercial furnace I got given from a local tech college gas fired [we aint got gas in our house] but it's got a tangential entry tube & I've had the burner in the workshop for a few yrs now & I never bothered with it but now you've spurred me on I'll rig it up many thanks for the info. Graham.

Not a bad casting considering the level of pattern preparation. Almost like you know what you are doing :) Great to see you up and around. Keep healthy Martin. Thanks for walking us through the process. What do you use for a fluxing agent? And did you degas this pour?

@olfoundryman8418

4 жыл бұрын

Mark, Almost no pattern prep on purpose just to see how it went (Nigel was curious and so was I) Keep healthy? Yeh, well, that would be nice but still standing as they say just with some difficulty. Flux is "coverall 11" by Foseco it is what is called a "drossing off flux". No, I did not degas this pour. While it is my habit to degas just about all my sand cast work I did not bother here as a little gas will help the feed and the quality requirements are not high (nothing aerospace with this job) and no extensive highly machined areas to show any gas. I sometimes tend to think that people get a bit obsessive compulsive about gas. It is usually so fine that most people will not see it - I mean we have people trying to degas with things like washing soda these INCREASE the gas level and yet they think they are doing a marvellous job because the machining finish on their unheatreated castings will not show the fine gas bubbles - the soft surface just flows over and covers up the bubbles as they are usually way less than 0.5 mm. What they see and call gas is most likely air bubbles caught because of silly gating methods. My advice on degassing is generally don't bother unless the work is critical or thick. Just use good clean dry metal melt quickly don't get to hot (unlike here😏 ) don't stir the metal use good gating and pour without delay little gas that you will not see anyway and no air!... Martin

@KravchenkoAudioPerth

4 жыл бұрын

@@olfoundryman8418 Keeping above the grass is the main thing I would think! I say it that way because I know you have a sense of humour. I agree that most of the porosity in KZread castings is the fault of the silly washing soda myth. Plus really bad pouring methods and practice. Way to large sprues. Overheating and prolonged heating as you mention. I pay attention and watch the machining of casting shown. So manyof them have large air pockets. So many people use uncoated steel crucibles and this creates it's own troubles with the aluminium eating away at the steel and reacting with it. Same goes for pouring into cans and tubes. You can do it but it rarely delivers a useful casting. Hoping you get to finish this series Martin. You are a fountain of practical wisdom. And You will be keeping me busy and thinking for some time to come. Mark

@olfoundryman8418

4 жыл бұрын

Mark, I see we both read from the same play book :) I actually started on YT to counteract some of the large sprue washing soda pushers out there (I regret my lack of sucess but I am still trying) I have been at this casting lark for, I think its now, 65 years and even an idiot like me has to learn something in that time! I do intend to finish this series grass above not withstanding. I Hope too that a few more series will come out, like why washing soda does not work etc., How to melt copper (nobody but nobody does it right). Ihave so many ideas for videos but I just need to live to 1000!... Martin

@KravchenkoAudioPerth

4 жыл бұрын

@@olfoundryman8418 Copper would be awesome to do a video or series on. Sure washing soda works. It works to make problems in the castings!

Siempre es un placer verte trabajar Martin, y aprovechar a mandarte un abrazo desde Argentina...está de más pero, buen trabajo!!

@olfoundryman8418

4 жыл бұрын

Daniel, Thank you my friend - A hug back to you from Australia. In many ways our two countries are alike, the love of a good beef barbeque for example.... Martin

I would like to get some of your 'exothermic'. To try in my place. It sure looks like thermite in the video. What is the stuff and any hope of getting small amounts in The USA?

@olfoundryman8418

2 жыл бұрын

Ron, I am in Melbourne Australia. I buy my exothermic from Foseco its called Ferux NF. Foseco have a factory in another Australian city but they ship the 25 Kg bag of the exothermic to me, I think the last bag I bought cost me about $165.00. The material cannot be posted as it is classed as an explosive! And carriers are supposed to be especially licensed to transport it. It does indeed look a lot like thermite and no doubt it is quite similar but probably contains things to slow the reaction down (sand?) and also things that seem to expand and provide insulation after the fire has died down. The only way I think it likely that you'll get small quantities is to find a small local foundry that uses it and while waving cash money ask them if they wil sell you a few pounds. If the first foundry says no then ask another - you could end up with a useful contact to help out with other things! Go in the mid mornings as many small foundries pour in the afternoon and are too busy then to even talk to you.... Martin

In the next video when you make multiple parts, can you show how the off-side part works. My understanding is offside is used with non-flat parting lines. I just can't envision how that part is used. Thanks.

@olfoundryman8418

4 жыл бұрын

Jim, How to use the oddside is a big part of the next video. Making of the oddsides was one of the big improvements made following the first trial moulding and casting videos. I have already shot the making of some of the "For Real" moulds and I do clearly demonstrate the use of the oddsides. I aslo make one mould where I do not use them as not everyone is going to 3D print the patterns and therefore may not be easily able to make the oddsides -the difference is quite stark but don't worry it is very simple and easy to use the oddsides....Martin

@JimHensel

4 жыл бұрын

@@olfoundryman8418 Thanks Martin.

Hi sir i have problem.What coating can be used to improve the quality of the surface in co2 sand?

@olfoundryman8418

4 жыл бұрын

Masoud, Yes, I too find that CO2 sand gives a rough finish - its one of the reasons I do not like CO2 sand much. However there are a lot of commercial mould coat products made by people like Foseco that you can use. I have seen people rub the core with either talc or graphite in an attempt to fill in some of the inter sand grain holes but this risks abrading the sand away. You might do better with spraying or painting on an mix of alcohol and graphite (talc may work too) burn all the alcohol off before using the mould. You may have to experiment a bit with the alcohol and graphite ratio. You could substitute water for the alcohol BUT you then need to thoroughly dry the moulds and you may need to add suspending agent like clay (NOT bentonite) or CMC to the mix.... Martin

@masoudpoorvahab849

4 жыл бұрын

@@olfoundryman8418 Martin, thank you very much for your help🌹

Excellent vid ty. Can youu talk a bit about how u got started in casting, i.e. where, what company, who were yr teachers, what was the state of the industry in yrr younger days, what types of metal did you start with????ty

@olfoundryman8418

4 жыл бұрын

Hrxy1, Long story, short version;- age 10 -12 made fishing singers in loose dry sand moulds lined with wheeties packet cardboard age 14 melted down aluminium conductor scraps using wood fire from re-electrification of road where I lived age 16 made teaspoons that melted in tea read "Metals in service of man" inspired by all of it but particularly by 4 pages on casting the propellers for the QU E series Realizing that geology, my first love, meant a life in the outback constantly moving around I decided to study metallurgy and have never regrated this choice 1963 - 1965 Set up small sand foundry about 1964 got some decent sand 1968 Worked as foreman in gravity die foundry 1973/74 Rebuilt furnace after moving about 1975 same furnace with same lining today! Have worked at a few other foundries over the years with last being as foundry metallurgist at Brake and Clutch (broken crutch) When last job ended ran own foundry full time to keep wolf at bay - not a good living but we survived tolerably well. Now make very little on a commercial basis - age has caught up In my younger days the industry was probably at least 4 times its current size there were foundries and pattern shops small and large all over the place Apart form my metallurgy studies I am self taught with a lot of reading along the way, with a thirst for knowledge and a tendency to always consider what I was told/read but to always look for newer better more accurate info from good sources. I learned early to sceptically respect the "old Hands" Their information was invaluable but could be outdated and dogmatic.... Martin PS, Hell - what happened to those 65 years?

@hrxy1

4 жыл бұрын

@@olfoundryman8418 no , no , no not in words but in video form. I like to hear you talk. Yr not boring to listen to . no offense intented for wring back to me obviously i ll read it but would prefer vid ty

@hrxy1

4 жыл бұрын

The last bit doeznt make sense, typing errer.

@hrxy1

4 жыл бұрын

Also i would like the long story long version, pls, ty

800 degrees maybe too much? 710-730 should be spot on for 6 mm plate section Lm25. Test the "T" junctions may still have dispersed low level porous shrinkage if needing long term extra soundness?. [single riser dead center on the back should pick up both feed paths]

@olfoundryman8418

4 жыл бұрын

Thesilver, 800 a bitt too much -y ou betcha - no doubt about it. But in my defence my furnace jumps really quick once melting is complete the temp just rockets with a small crucible like that. I was actually aiming to pour at about 760, still high but I needed to get the casting and I had no idea how it was going to work - this was only a trial casting that will not be used. The plate section here is actually 5 mm thick and surely the temp needed depends on how extensive the section is. The "Ts" may have porosity but I would reckon it to be at a very low level as the back of the pin lugs is flat and very shiny - none of the dull appearance or surface sink that would indicate any porosity. Perhaps a bit of gas helped too as I did not degas.The single feeder on the flat section dead centre unfortunately has a problem - it is between the sand retention ridges and thus hard to remove - a milling machine would do it nicely but that is contrary to the very idea of this project i.e. the minimum tool requirement. I am not sure that it would be that much better anyway - feeder gating as used here is about as good as you can get as the feeder receives the hottest metal and the two pin lugs are quite close to each other. But that was the idea of this trial to see if it would work in as easy a way as possible. As the sides proper - to be poured soon - are in the main longer than 150 mm and thus the 5mm section more extensive I will start pouring with the longer ones first at 750 to 760 finishing up with the 150 at about 730 to740 I will progressively pour and break out to monitor progress and if any show signs of edge rounding or of overly rough finish/finning etc I will adjust the temp accordingly. Thank you for your input , I do appreciate it - its nice to have someone keep me on the straight and narrow... Martin

@TheSilversheeps

4 жыл бұрын

@@olfoundryman8418Thanks- Appreciate your comments yes5 mm pushes casting temps up a bit. I'm guessing in the bigger picture is a concept called "fitness for purpose'.As I could also very well mentally picture the residual gas porosity offsetting the shrinkage in the thermal centres if that is the case that same existing setup might suit a 2:1 setup where 2 castings are feeding off one riser i.e more volume-based style feeding. please keep us posted I'm enjoying seeing this progression to a simple real all Round functional box design (next thought would a matching slotted spigot and divot, help reduce design to a single bolt at corners? I'm thinking this is related to how fast do you need/want/replace and to adjust box sizes?) ... Joel

@olfoundryman8418

4 жыл бұрын

Joel, Part of the problem is that I am a panicy old bugger riven with doubt and fear as to "will it run" or has all that mould making work gone down the tubes so I tend to err on the hot side a miss run is a total loss and hot pour usually not so much. "Fit for purpose" certainly applies here - this is no aerospace project and I have to allow for the possibility that some who try may not be sophisticated foundrymen - it has to be an easy and forgiving process all the way from pattern making to final bolting of box sides together. I looked at two per box around a central feeder but, alas, my boxes are not wide enough, pity as two per time seems about 10 times 😀 quicker than 1 at a time. We always figured that by the time we have finished this series the design will have moved further ahead and in fact its moved a long way so far but we do hope that others such as yourself will put their two cents wort in and come up with yet better versions and certainly the one bolt may be a way to go. One could actually try it very easily with these boxes by carefully marking out a centre hole between the two existing drill divots. Maybe the pattern could be modified to include a third divot? The pin lugs have now been altered, they have a divot for the grubscrew (to hold the dowels in) and a centre line to mark where the dowel holes should be drilled (in one direction anyway) Will do the best to keep you posted. I have enough shot now to do a video on the "for real" moulding I hope to cast the first 10 of these next week and do the last 6 the following week or so. Have to see how I go my balance is shot and I have chronic fatigue - OH, old age is grand..😰. Martin

@TheSilversheeps

4 жыл бұрын

​@@olfoundryman8418 Martin as this is a public forum of sorts. I have at least 4 things in mind: 1. Please check that you first casting you have made for warpage against a flat surface and a set of feeler gauges like a plane of glass. if history is anything is anything to go by and patternmaker contraction, i suspect the thermal action will be causing the cope flat surface to curl upwards at the ends ever so slightly maybe in the 0.25-1 mm before you cast anymore. if there some counter warpage may be the solution -upshot- it could be causing an exaggerated dimensional instability on assembly. 2. Check out the Foseco foundryman’s hand book it has some nuggets of information in there about relating section thickness to casting temperatures so as to make better approximations on first pour work. it suggests along the lines of a casting temp for 3-6mm thickness, then one for 6-13mm, then 13-25 and finally one for 25mm and above. [i do have a copy up in the attic and will email to you later if interested?] 3. Looking at the videos from overhead when you knock the poured castings out. It seems to me that the green sand mid sections drop first which makes mechanical sense. so think along the lines of a version 1.3 where your .stl files are modified to include cross hatching say starting 3mm high x1mm wide@20mm on a dual diagonal angles tapering to nothing at edges to help sand retention. i think this would likely help in reducing cope or drag drops and improve the sand/box stiffness 4. a change to a "U" shaped cross section plan view to lighten out the lug section from existing rectangular section might be a version 1.4 mod 5. Finally I'm sorry to hear you suffering from "chronic fatigue syndrome" it must be a real downer in some respects. Keep the hope up... There are many new medical advances being found every day, "a ‘martini’ a day "may help keep the doctor away” in the mean time! :

@olfoundryman8418

4 жыл бұрын

Joel, 1, Just went out and checked and warpage is 0.004 inch over that cast side. But it seems to be mainly associated with the remains of the brim from the 3D printing i.e. the unevenness is right on the bottom edge of the print and is only associated with the sand retention ridges along the top and bottom of each side. I guess the real worry though is if the 45 degree ends are at all warped and I am not really going to know that until I have sufficient sides cast to check by placing them against each other and seeing what sort of box I get i.e. how square - Fingers crossed! In the past I have sometimes found to have a warpage problem but mainly associated with multiple gates to the same casting - runner and casting pull differently. 2. I do have a copy but it is a bit old (1968) and it does not even mention LM25 (356) (our 601) But I do admit to pouring too hot rather than too cold. If you could email the info I would be appreciative "olfoundryman@gmail.com" 3. Have a full length sand retention ridge top and bottom of each box side - have always used this - I don't like drops either! These ridges - like the edges on a one sided "I" beam also help with box rigidity. 4, Not to sure what you mean here, can you do a sketch and email it to me? 5, Its a bit strange really as I am not too sure that I believe in CFS mind you these days I am not too sure that I don't! At lest with time this MAY get better but the balance will never improve and it takes real effort to stand up move around and stay standing. Sitting and particularly lying down I can rule the world - standing up, eh, not so much! A martini a day ,now if only I drank! 😊… Martin

great information, kind of you to share...one question you did not degass with nitrogen to get hydrogen gases...is that ok for small amounts?

@olfoundryman8418

4 жыл бұрын

Stuart, It is my habit to degas with argon for all my sand work. But mot of it gets machined to high finish and gas would become possibly obvious. If you look at my reply to a comment made by Kravchenko Audio about 6 hours after yours there is a bit more of an explanation re gas. I generally believe that for most hobby work degassing is pointless and in any case many people do it so badly that they wind up with more gas not less... Martin

@smca7271

4 жыл бұрын

@@olfoundryman8418 thanks, read your other reply...castings I have machined were holey but not less than 1mm so its my pouring and I will not get hung up on degassing... appreciate all your videos, lots of info out there , but nothing like being able to see how it should be done,cheers

@olfoundryman8418

4 жыл бұрын

Stuart, Generally air bubbles will be all sorts of sizes with a preponderance towards the top of the casting often caught under the top skin, larger air bubbles can break through the skin and escape but they can leave a damage trail behind them. If your casting is thick and big and therefore takes a long time to solidify and your gas level is high you could get gas up to maybe that 1 mm but it would be unusual. If you like send me some photos to olfoundryman@gmal.com and I will have a look... Martin

@smca7271

4 жыл бұрын

@@olfoundryman8418 thanks for the offer but the part is long gone now...with all the bubbles(pretty large) I tossed it...but I will have another go with more thought to the sprues and temperature...I have argon .... but I figured with all the mucking around degassing I would probably make it worse not better..thanks again for the informative videos.

👍👍

@olfoundryman8418

4 жыл бұрын

Scrufffy, Glad that you liked it... Martin

Hi Martin what sand dit you use

@olfoundryman8418

4 жыл бұрын

Coenie, I use a natural clay silica green sand - it came from a quarry about 50 Km from me. Al Idois sieve it to remove the few largish (1 - 2mm) pebbles it contains, add the required amount of water and its good to go... Martin

@coeniecastelyn4961

4 жыл бұрын

@@olfoundryman8418 thank you 👍

Metal looked really low viscosity. Was that an illusion or was that the high temp? Your part looked awesome to me. I couldn’t tell that there was anything wrong. No obvious holes or anything that 2 minutes with a file wouldn’t straighten out. But I’m sure you gave a better eye fir these things, I hope you go into details on the flaws and how you fixed them next time. I always learn something in your channel.

@olfoundryman8418

4 жыл бұрын

Rv4, In the main an illusion I think. I doubt the extra temperature would do all that much to lower viscosity, mainly it just gives a larger temperature that the metal has to drop through before it gets too solid to run thus -hopefully - it will run further. Yes the casting was quite usable - not pretty but prettiness is not needed here. A little mould edge loss but as you say nothing a file would not fix. I have already shot the "for real" moulding and some improvements are covered in that but when editing I will try to keep flaw avoidance in mind.... Martin

what type of furnace do you used diesel or gas

@olfoundryman8418

4 жыл бұрын

Aidian, Diesel - way cheaper than gas and it doesn't freeze in the bottle either... Martin

What is the exothermic that you talk about?

@olfoundryman8418

Жыл бұрын

B Ross, The exothermic is called "Ferrux NF" it is made by Foseco..... Martin

👍👍😎👍👍

@olfoundryman8418

Ай бұрын

joell, Thank you.... Martin

I snuck this video in during work this morning, couldn't help myself, but here I am again. I know the question was asked earlier, but any details of your furnace would be appreciated. I'd like to build one in the future... Appreciate this series of video, motivation for a furnace.

@olfoundryman8418

4 жыл бұрын

Rich, Furnaces are easy! they just rely on burning a lot of fuel in a small hole as quickly as possible - its just got to get hot if you do this! I built my main furnace about the mid 1970s and if I was to do it again (unlikely) I would do it a bit differently. First thing is to decide what sort of fuel - electric oil (diesel) or gas. Electric is quiet but slow, Gas is the easiest burner design. Oil is the cheapest fuel. For a quick start you could just buy a Devil Forge they seem to work well enough although I am not keen on them for the way the lid works one could be modified to fix this problem though!...Get motivated and Just do it!... Martin

@richwest2929

4 жыл бұрын

@@olfoundryman8418 Yes sir, got-it, a lot of fuel and a small hole...sounds easy, what could go wrong...;) You did answer one of my questions about fuel choice and why. As well, I think your lid mechanism is intriguing, it seems to operate with much ease and control. Lever handle, counter weight and stable pivot post...I'll binge watch some of your prior videos for more ideas. Again appreciate this molding box series, always something learned from a seasoned foundryman.

@olfoundryman8418

4 жыл бұрын

Rich, There is no counter weight on my furnace lid just that lever arm which sort of has a cam on its end this operates against the end of the inner tube (welded to the furnace body) around which the outer tube carrying the lid slides up and down. The tubes are two sizes of steel water pipe. The devil forge lid suffers from the problem that it exposes the operator to the hot underside of the lid when the furnace is opened - you already have enough radiant heat from the inside of the furnace without needing more form the underside of the lid! Choice of fuel may be different according to where you live I guess it would be a local price per unit of energy thing. Gas is very convenient as it is (relatively) easy to build a burner for BUT I firmly believe that you DO need a blower with gas just as with oil to get a decent air/ fuel ratio. Many gas burners run rich and it is best for the metal and economy if they run lean (about 2% Oxygen in the exhaust gas) hence the need for a blower….. Martin

@richwest2929

4 жыл бұрын

@@olfoundryman8418 Your video, Furnace Light Up...tells me enough. Great design! kzread.info/dash/bejne/lZicj7Z8XdyxdLw.html

looks like a good result to me. Ok, ok, I've not done any more than make muffins once, but I'll be happy if my first proper attempt gets detail finer than 10mm pixellation bahahah

@olfoundryman8418

4 жыл бұрын

Jeff, Do you mean real muffins (baked in an oven) or metal ones cast into mummies muffin tins? If the former you are one ahead of me if the latter - eh - not so much ahead 😊… Martin

I'm a little confused about the need for deep dimples for the corner bolts. If they're just casting vague, no offense, it would seem that there's no need for them to be as large.

@olfoundryman8418

4 жыл бұрын

Lunky, They are large for two reasons 1. when drilled for 1/4 inch or 6mm bolts they will leave a nice chamfer 2. if they had been smaller the sand cone forming the dimple would have been weaker and broken away from the mould you will notice that I had trouble with this anyway (we have now radiused the edge of the dimple to get rid of this problem - we hope!)… Martin

Can you get aluminum too hot? Wondering if that'll change anything in my castings.

@olfoundryman8418

Жыл бұрын

Silicone, Yes, overheating is bad. Anything over 760 deg C is likely to cause increased hydrogen gas problems. Higher temps increase oxidation and thus increase the amount of oxide floating around in the metal - this lowers fluidity, interferes with feeding, lowers strength and ductility. Higher temps also lead to increase grain size and this also causes strength ductility and feeding problems as well as hot cracking tendencies... Martin

Hi sir, I have a question. Do we have to melt the flask first and clean the melt and then do the degassing or do the degassing first and then the flask?

@olfoundryman8418

2 жыл бұрын

Masoud, I melt the metal - then I degas it - then I add 5:1 tibor grain refiner (about 1 part in 1000 of melt) -then I add a little drossing off flux to the top of the melt, lightly stir this in to just the top surface to dry up any dross. - then I remove this dry dross and pour the casting the casting... Martin