I’ve been watching TallyHo from almost the beginning. Y’all are doing a great job. It is very interesting. And I really never thought about it. But it is great to know we still have craftsman in this country that are able and love to do these things.

The amount of patience is remarkable.

Thank You for sharing this with us. Very appreciated.

I appreciate these videos very much sir, nice to see what really goes in to making a mold like this.

Anybody that thinks Clark is out of his league has no idea what they’re talking about. I don’t think a modern foundry would touch this job. This is true craftsmanship almost lost art so whoever wants to talk smack about Clark needs to think about it next time before they start typing.

@stevewright201

2 ай бұрын

I completely agree with you it's just so interesting watching Clark big thumbs up

@TheUncleRuckus

2 ай бұрын

💯

@AbbeyRoad69147

2 ай бұрын

Hmmmm.... honestly I feel WindyHill could be doing a lot to make their lives easier, like making more complex tools. Also, there are sand mixes with a small amount of epoxy that dont fall apart. There are also lost wax techiniques. I have never poured iron, but it seems logical to me.

@kennethpole2439

2 ай бұрын

A lot of tiktokkers are trash talkers.

@rjw8316

2 ай бұрын

Agreed, never pay attention to tiktokkers as they never add anything of value. Also, I suspect anyone who uses a Chinese platform. @@kennethpole2439

Anyone who doesn’t get why the floor is sand has never dropped molten metal on concrete 😮

Hi Steve, pay no attention to the Tik-Tok twits there are plenty of us oldies out here who ate extremely interested in all the minutia involved in this creative progress. As someone who has been watching Windy Hill Foundry, Kieth Rucker, Dave the Pattern guy and Leo and the Tally Ho rebuild I am fascinated by the demonstrations of the skill of all participants. Ignore the impatient idiots and carry on making things your way. Thank-you for the time and effort you put in to this Video.

@misiluki100

2 ай бұрын

Amen

@jamesspinks716

2 ай бұрын

My old wind up station clock goes Tick Tock, is that what he’s talking about?

I've been watching Tally Ho since Leos 1st video. To see craftsmen working on the capstan rebuild including the trials and tribulations of formwork is a sight to behold. It shows just how much workmanship went into the original build over a 100 years ago! Modern day engineering and manufacturing doesn't give credit to the processes involved to churn out complicated shapes such as the simple capstan on Tally Ho! I always marvel at the feats of engineering involved to make these old, but very functional items. Well done guys, I doff my cap to you for your persistence and craftsmanship.

@10swatkins

2 ай бұрын

Thank you very much. It's a process to make this happen...

@PETERFWESTON

2 ай бұрын

I see it and marvel at the skill level it takes and with modern equipment. But just think, how did they make these intricate pieces with the tools they had at the time. Brilliant.

Clark, I was on a US Navy sub tender in 80s, we had a huge foundry in the bottom of the ship, in my spare time I hung out there, they were still using techniques from the 40s because they were proven to work, you're doing a great job, that's hard to do.

@sheep1ewe

2 ай бұрын

I saw a documentary where they did use led castings as backing for sheetmetal work on board as well, must say that i hawe the deepest respect for those old scool guys (and those who had the opportunity to learn from them)!

@smitm108

2 ай бұрын

A foundry on a ship? Amazing things you learn on these channels …

I think the best part of watching both you and Clark working through these process’s is your attention to learning through the process. Every failure creates a learning potential. Clark obviously goes through a litany of thought based on passed experience, which is vast..

@10swatkins

2 ай бұрын

I just stand there, film and make off the wall suggestions based on little to no experience... Hey, I might have the makings of a Commenter on KZread videos!

An excellent example of patient perseverance

You guys are great and these videos show the kind of skill and resilience needs to make these one-off parts. I am in awe of their talent to make this happen. GREAT WORK ALL YOU GUYS!

@10swatkins

2 ай бұрын

Thanks MIke....

Love all the work and thanks for filming it!!

@10swatkins

2 ай бұрын

Thanks for watching!

I'm starting to think I'm not going to live long enough to see this work. This is a big job and the process the original parts were made is becoming a lost art.

@10swatkins

2 ай бұрын

Sure you will :) Well maybe ::) Clark will have a video out on the finished piece next sunday I believe... Can you hold on till then ?

@william6526

2 ай бұрын

@@10swatkins At my age it's a real crap shoot.

I really like how you show that each prototype pour is a learning process which has be to iteratively improved by the lessons learned from the previous failure.

@10swatkins

2 ай бұрын

That's what I show on this channel. The good and bad so people can learn too!

Good day to you all. Steve, , , I sure don't spend as much time as I would like visiting with you. As when I am casting pure silverI run across most of the difficulties the fellas at Windy Hill do but at a far smaller scale and just a 2 piece flask/casting. Grams instead of pounds but the problems that pop up are identical in every way. What really makes me chuckle is our process while working in a dirty, cobbled looking setups produce such beautiful pieces from within them. Sand, dirt, oil's, scary high heat create the things we need to make our world more enjoyable or liveable. When the flask had that blow out your hearts must have done the same. All that work now needing a newer approach to the pour are still hanging in there. Many times I have had to walk away from a fail to return with a new gusto for that perfect result.Well folks, All I can say is ONWARD, Yer all doing great ! ! !

The patience and perseverance of you guys is amazing. Keep going!

@10swatkins

2 ай бұрын

Thank you! Will do!

Great comments on what was happening during the pour and making the 3rd pour. This mold definitely takes a LOT of preparation and care to get a pourable sand casting shell. Steve, Thanks for sharing!

@10swatkins

2 ай бұрын

Thanks again!

Great video Steve and thanks so much for your help👍

@10swatkins

2 ай бұрын

Happy to help

@kens.8834

2 ай бұрын

Amen, Steve and Clarke !

A carpenter adjusts a workpeace bit by bit. A bronze cast just requires a few attempts. Craftsmen at work can be recognized. And craftsmen you are all! This is just what it takes. There is a foundry in my vicinity. I know that these guys are hardly ever "getting there" at first pour. Patience does the trick! Overall, I love this video. It shows that pouring metal is a craft unlike and still like any other. This video, in the context of all the others, is G O L D !

You have an amazingly well trimmed beard, sir. You remind me of my first industrial tech teacher, God rest his soul.

@joshuaferguson5756

2 ай бұрын

By the way, you said exactly what I've been saying to the dummies posting on Clark's videos. It's harder than people think to make cast iron parts of that size. hell even Lodge chucks close to 5% of it castings, and their just doing tiny pans

There are a lot of things. I would like to say about how awesome this work is... I guess what I will focus on is how well you guys understood what it means to "help" as opposed to influence a project. I am sure that is why Clark likes having your support so much. Really awesome patience, tenacity and craftsmanship was exhibited in this project. It is very much in keeping with the Tally Ho experience. Thanks for filling in all the details that Clark edited out of his video. Now this is real drama with impact!

@10swatkins

2 ай бұрын

Oh, we tried to influence it ! The next three days of the project were with Clark, Josie his wife and me. I've been trying to decide how to make a video to show the rest of the story....

Love your video’s!! No rush, well explained. And honoust… not leaving faillure out!

@10swatkins

2 ай бұрын

Thanks so much!

Increíble artisans, people who comment who have never been to an industrial or artesanal foundry are truely commenting out of turn. The work that windy hill foundry, Clark and his team, are carrying out is second to none. This is sadly a dying art form, from AOB it’s sad to not see a younger generation assisting and learning from true masters of their craft. The finished product will be incredible (Clark will never give up, something the younger generations should learn) and will form an integral part of a unique project that is Tally Ho. Keep at it Clark et all…. And looking forward to seeing the final successful pour!

@kens.8834

2 ай бұрын

I couldn't have said it any better !!!

100% cool that you told us about the "blurs"! Thank you!

@10swatkins

2 ай бұрын

My pleasure!

Thank you from for the most instructive and interesting videos. I have learned a lot about the skills and pitfalls of foundry work Your perseverance is almost heroic! As we would say in Australia, 'don't let the bastard beat you.'

@roytally8329

2 ай бұрын

Or to paraphrase, "Don't let the bastards grind you down!"

Thanks for supporting Tally Ho!! I am subscribing to your channel because you support Leo!

@10swatkins

2 ай бұрын

Thank you too! A couple of years ago I wanted to go spend two weeks helping work on her but someone told me Leo wanted people for at least a month. I can understand why, making sure they knew what they were doing, where the tools are and such.... Ended up going to work on the SV Seeker and that was fun too :)

WOW....JUST WOW. What frustration. You guys have more get up and try than I could.

@10swatkins

2 ай бұрын

Well it's a job that needs finishing or else Leo will be floating all over the place with a hook :)

Total respect to you guys… you have the patience of angels… I think I would have turned the air a deep shade of ultra violet !!!! 😊

Apprenticed as a sandbox moulder on a sand floor using cores, nearly 60 years past, basic process will never change. They work simple

Hell of a job!

@10swatkins

2 ай бұрын

Clarks wife will not let us stop :)

i remember doing some casting way back when i was in school, so long ago i forget what it was i made, only casting in aluminium - but i have a smile on my face watching this, i bet the old boys who made these originally are upstairs looking down on you with a big grin - 'we used to make a dozen a day' its a hell of a skill with much patients, i'd be tearing my hair out - great video and thanks for sharing

@10swatkins

2 ай бұрын

There are three more days of work after this... Guess that's why I'm now bald :) Back in 1975 my High School shop had a great foundry. The natural gas furnace was only hot enough to pour Aluminum but we all had three required foundry projects to do.... Those were the days and I'm sorry my kids missed out on all of that :(

@patchmack4469

2 ай бұрын

@@10swatkins indeed - i guess in many ways we have come a long way - i dismantle some old stock aviation parts, i been quite amazed at some parts being cast inside others, of course CNC modelling plays its part today, creating some very complex parts - they can be a real git to get apart to separate metals, often having to butcher with angle grinders and cutting discs

I love that he uses hand bellows instead of compressed air to blow the mole clean

@10swatkins

2 ай бұрын

Once you put in all the work to get to that stage it's a good idea to be careful!

A lot more difficult than I expected.

THANK YOU for explaining the pixelated bits. You read my mind; it WAS drivin’ me nuts. And thank you all for the care. Wise choice.

A lot of people forget that foundry work really is an Art, a highly variable craft more than a perfect science. The molds are impacted by the environment they are made in, sand recipes get adjusted based on changes with supplier, the current temperature and weather, the size of the piece being poured & how the mold is composed. There are general recipes to get you in the ball park but particle size, overall consistency and even the very composition of those particles(silica/quartz, etc) will mean 2 people both starting with equal amounts sand and water and binder may be actually looking at 2 very different things. I wouldn’t be surprised if the quality of the water had a noticeable impact and it’s up to the Foundry Master/ Site Boss to make these adjustments. Even after the molds are made each one will have its own unique considerations made for where vent holes and/or risers go, if a catch basin for initial turbulence is needed or other special considerations will be used to feed the casting, the overall size/draft of the pour spout and those feed gates. With so many variables it’s has to be expected that things won’t always go right the first time. Every new pour is unique and another notch under the belt toward becoming a master of the craft.

@10swatkins

2 ай бұрын

Well said! Infact Clark had to make adjustments adding and subtracting clay and other things to get that sand just right for the inside of the casting... The part that broke off during the last video was really difficult to make release and not fracture because of the pattern and general shape.

I have taken away from all of this capstan mold work is, "If it's so easy, go out and try it" ... Anyone else would give us a 30minute vid with everything working to perfection, but what would we actually learn from that? .... well, some would think "look how easy all that is, anyone could do that".... and that would be the wrong message and a disservice to the fans/viewers. I worked in a foundry in HS as part of a student trades program and remember pounding sand and pounding sand, and pounding sand....and even then, there's no absolutes dong the simplest castings with aluminum. When there guys started on the 3 part flask with those inserts I imagined a dozen ways this falls apart and fails and these guys know their shit.

Admire the craft, dedication, persistence and camaraderie that goes into that Tally Ho Capstan, I guess just than one piece of the whole boat is half the cost of the project, but its worth it imo 🙌💪🙏

@10swatkins

2 ай бұрын

Leo does not have enough money to pay for what went into this part of the project... Tons of donated labor here alone...

Wow just Wow. From Australia with all best wishes. My message to Gen X , please watch this and understand perfection comes with patience, NOT Tic Toc. So enjoyable. Thank you. Cheers.

@wazzawiseonenew

2 ай бұрын

Had to add. How many hours of Experience, knowledge and understanding do you see here?. My estimate is 100,s, definitely not 10, 20, 30, seconds of Tic toc.

@earlchapman8729

2 ай бұрын

I’m pretty sure you meant to address this to the millennials. Trust me , Gen X has lots of patience as we spent a majority of our upbringing without the internet.

@TheUncleRuckus

2 ай бұрын

You're thinking of Gen Z, and Gen Alpha not Gen X. 👍

@SuperDrumwolf

2 ай бұрын

and YOU'RE generation has absolutely ruined everything! thanks but no thanks. left us with financial disasters, more communists, etc.

I have poured iron into green sand molds. It is very difficult. So many things have to be just right for it all to work.

Amazing skills

Thanks, Steve !!!! ..... I've been waiting for this ! Maybe Clarke could use your help on more of his videos ... WELL DONE !!! -Ken ( long time subscriber to your channel and Clarke's ) .

@10swatkins

2 ай бұрын

Glad you enjoyed it

Clark, for someone who has no idea how to do this, you're doing great. Keep going. I couldn't begin to do do the work you do. I appreciate the failures too, most of my work ends in failures, so it's good to see real people experience real issues.

@10swatkins

2 ай бұрын

Failures are part of everything. How many times did Space X try to land the Falcon before they got it right? "Falcon family core boosters have successfully landed 281 times in 292 attempts." I think Clarks record of 4 pours for this casting is outstanding considering how difficult the interior of the part is.

35:42 HeHeHe this sound reminds me of those Looney Tunes sound effects with the big bad wolf on his tippy toes 😂😂😂

Fail is an acronym for "First attempt in learning"

@10swatkins

2 ай бұрын

People don't seem to understand that...

Good grief I had no idea. I will look at cast pieces in a different light from now on. And a massive massive applause to there perseverance.

This looks harder than I thought; great to see you guys get genuinely expressive and clearly it’s annoying. But the first thing he thought about was his friends travelling. I’m guessing they lose profit every time this doesn’t work out. Thanks for showing us this casting.

@10swatkins

2 ай бұрын

I'm the friend and none of the helpers are getting paid :) We do this for free and foot our own expenses just to help Leo and more importantly Clark out,

I watched the disassembly of the capstan and was appalled at the amount of heat and force that was being used. From experience cast iron pieces that are seized together from exposure to the weather, dust and rust had the greatest sucess was by warming the parts then spraying the joints with a 50% vinegar water solution, Warmed to the point where the water flashes to steam when sprayed using a trigger bottle. You may have to do this several times gentle tapping near the joint might hasten the process. If you can suspend the parts so the weight of one piece would help separate the joint. I have seen cooking oil, applied with a hand oiler, used for cooling after the pieces were warmed. The Vinegar and oil will make you crave french fries go for lunch perhaps when you come back,you'll find that the pieces have separated.

@10swatkins

2 ай бұрын

I was not there when that happened so not much I can say.... Thanks for watching

1:27 - Just got my first cam-lock spindle lathe, oh, 10 years ago; what a pleasure! It's also rigid enough to allow part-off cuts which took forever on the former lathe. At my age, I could use a lift of some sort. 9:12 - Sorry to hear Clark is concerned about it, but more than happy he is taking measures to perhaps avoid future issues. 39:09 - Good luck!

@10swatkins

2 ай бұрын

Check out this video.... kzread.info/dash/bejne/hod6upSte7q3cps.html An easy to make jib crane .......

Wishing you all the best guys. You have the determination so I'm sure you will succeed.

@10swatkins

2 ай бұрын

Oh we just stuck with it till it turned out good...:) Clark should have the final video out on his channel this week... I am following along with the longer videos that show how hard it was, the problems and how Clark overcame them...

Well a few o bugger moments . Remember its a feature not a fault !! You guys are doing a great job . We all have out falures its how we deal with them .. Thats why you succeed !! We are all learning every day . Keeping our heads working . When most of us are past the best before but not the use by .. go for it .. hi from the land down under

@10swatkins

2 ай бұрын

HI :) I was shocked that I didn't have to edit out any bad words :)

I watched an old British documentary, where they laid out and pre-fabricated a switch lead for a very busy rail interchange. They cast their own specialty "Frogs." The greensand was all stored on the floor, they walked in it while making the mold, scooped up what they wanted from wherever they were standing. One of those workers couldn't have been older than 14, but he was in it up to his elbows. When it came to the pour, he was ten feet away. No glasses, no shielding, no leathers ... I assume it was "watch and learn" training for the day he would be in charge of that huge hanging crucible. Anyhow ... one thing I did see that looked like a good idea was that they had banked the mold on all sides with the extra greensand on the floor. It looked like good insurance against a blowout

@10swatkins

2 ай бұрын

I suggest watching the third world countries mold stuff, there are tons of videos on KZread of them casting all sorts of crude lathes even. I keep telling Clark that the best way to ram sand is with bare feet! Must be because I saw it on KZread :)

@infoanorexic

2 ай бұрын

@@10swatkins I've seen a few of those, mainly out of Vietnam.

is there actually ANY shop in the world that could do this? Well I mean, SOMEONE cast the original. How did they do it? Appreciate the effort, and feel the frustration.

@10swatkins

2 ай бұрын

Sure lots of places.. But this is a one off and it take time to figure out all the little bugs in the pattern and getting the metal into the mold. Oh, not to mention the effort to figure out how the mold can be taken apart to remove the pattern.. Sort of like Leo taking 4 tries to mount the bowsprit... It's a process...

@flyerphil7708

2 ай бұрын

@@10swatkins Leo was just being cautious, and he knows what he is doing.

@bcbloc02

2 ай бұрын

I can think of at least 3 foundries that could do this part but I also am fairly certain it would cost upwards of $10k

I’m halfway through the video and am praying that you get a useable casting soon. An awful lot of work goes into this and I’m certain that many shops wouldn’t take this job on. I hope you are getting paid well for this. At first I thought when finished that the boat would be donated to the Albert Strange association, I didn’t realize this was going to be Leo’s personal boat. Wish the construction of my new house was being paid for by the public. 😃. Great work guys!

Hello Steve great video and the comment regarding floor pouring. Over here in the UK one of the very first cast iron bridges built in Coalbrookedale had over twenty feet lengths all poured on the floor. There is a very good documentary on television about the casting and a trial run was carried out on a mock build by the Army I think. Also there is a very early painting of the gorge with the original bridge in the process of being built

@10swatkins

2 ай бұрын

Clark is all hot to trot on it :) Of course I need to remind him that the floor keeps getting farther and farther away the older you get :)

Just bloody excellent video. From AOB (another older bloke) 😅

@10swatkins

2 ай бұрын

Glad you enjoyed it

Hope you got to lunch at 12:20. She meant it.

@10swatkins

2 ай бұрын

She fed us goooooodddd :)

Talk about hot stuff!

"...heck, I even do dumb things - I started making KZread videos!" - That's when I hit subscribe. LOL.

@10swatkins

2 ай бұрын

Welcome aboard :)

The old adage of "try, try, try again" applies here. I know it's easy to be an armchair advisor on these things, but would seem to me, the complexity of the bottom of the part should have a lot more of the white separation powder (whatever its called). I'm happy to see that it looks like it does on the remaking 38:53. I watched SV Seeker learn the hard way on casting his own parts. He tried again too many times to count, way more than you did. However, he was experimenting with different sands, flasks, and heating methods. He was learning as he went.

@10swatkins

2 ай бұрын

The castings on the seeker are really out there :) Everyone has different sayings and such... What really blew me away was Doug having the balls to cast up the 6 propeller blades :) Outside the front door of his house he had the shaft and propeller set up on a stand that allowed you to balance the prop.. Loved turning that baby everytime I went by :) It more of a little draft and too rough pattern that gave us trouble on the pattern removal. I spent 2 hours smoothing that out and then we did fine.

❤

how does 3D printing figure into these types of processes?

@10swatkins

2 ай бұрын

Not at all :)

I saw something back in 1984 that illustrates why a dirt floor is good for a foundry. I saw a piece of red hot steel drop 2 inches on a concrete floor and a piece of the concrete popped out of the floor. It landed about 5 feet away after bouncing off the guy who was working on the piece of steel.

@10swatkins

2 ай бұрын

That must have gotten his attention :)

I seem to remember from high school metal shop days of putting sand retention cleats in the taller bowl shaped molds to mitigate the inside of the mold coming apart. I could be wrong.

@10swatkins

2 ай бұрын

There are cleats on the inside of every flask to hold the sand there... The problem child is the inside of the casting is complex, rough, little draft and the sharp sand particles are rammed in there with force. We worked on the pattern and overcome all the obstacles in the next few videos :)

@patrickradcliffe3837

2 ай бұрын

@@10swatkins yes I saw those. We also set cleats in the sand on the inside of the bowl section I just just can't remember if they were refractory or not. They were these kind of I beam looking things. I remember it was deep wide dutch oven. The sand kept coming up in the center. The shop teacher used a couple of these cleats and worked like a charm. I also remember he wasn't too happy that we were gonna be heating and pouring so much iron, but he acquiesced since we were juniors and all of us had been in the same class together since freshman year.

Just a thought, have you tried using one of those cement vibrators or dare I say some sort of vibrator that you could tape to the top and then pull it while it's vibrating. I was thinking maybe that would provide the consistant and even vibration that would allow the mold to release easier. Just a thought.

@10swatkins

2 ай бұрын

I was ready to try a needle gun on it :) Lots of brainstorming was going on... The main problem was the mold shape and finish. Two of the central parts needed a little more draft as they were almost straight sided. They had a little draft but not really enough. Also the inside was a little rough... I learned last year that what I thought was smooth for a pattern was not smooth enough! I took care of that problem on the third day....

WOW

The whiny-ass tik-tok'ers ain't got a clue. Sir, you do what you do best. Pay no mind to the trolls and wimps. The rest of us understand. And appreciate the skill involved here. fjb

Steve, thanks for showing the whole process. Editing often makes these tasks seem much faster and easier than they are. I do have one question though., maybe I wasn't paying enough attention to your introduction.... are you implying that tik-tocers would benefit from pounding sand???

@10swatkins

2 ай бұрын

Well not really :) I imply that our learning ability has shrunk do to a shortened attention span and the lack of "wow" factor in most things we do. People are so conditioned to a 3 second rotation of pictures in a video that just listening to someone explain something is almost impossible for them.

@10swatkins

2 ай бұрын

Oh and that 12 hour day was edited down to just 38 minutes.....

Really makes you wonder how the original was cast a hundred years ago!

@flyerphil7708

2 ай бұрын

Just skilled workers.

@10swatkins

2 ай бұрын

Same way! I wonder how many times they had to pour to get a good casting ? Took Leo's crew 4 tries to make the hole big enough for the Bowsprit... I think 4 pours to make a really complicated casting with complicated insides and a pattern, we did not make, was pretty damn good :)

@flyerphil7708

2 ай бұрын

@@10swatkins skilled workers would get it right first time I’m sure.

Looking at the capstan components, I am sure they could be milled from steel billet instead.

@10swatkins

2 ай бұрын

Sure.... Wonder what that would cost?

Thanks. Now I'm afraid some dude is going to pile up some pixel sized blocks an try to blow propane thru them. People are frail in many ways. Another subject: Is it detrimental hanging some radiant heaters in the shed? Or, does that complicate the process? Or, a battery heated jacket or vest instead?

@10swatkins

2 ай бұрын

I am learning about heating :) My body has changed dramatically since the Heart Attack 2 years ago and taking the new shots for diabetics. Lose of 30 pounds of insulation, blood thinners and Monjaro shots have turned me into a cold weather wimp!

@johnmcanulty7341

2 ай бұрын

Well Yup, and you weren't acclimated to the cold. Same with the hot stuff: It take 5-10 days to acclimate for soldiers when they drop in to Djibouti and of course you, are not a young dude but, would likely survive. Ha! I guess Windy Hill does not get cool enough temps to put some diesel heaters to the shed? @@10swatkins

That is heartbreaking. Keep at it lads.

@10swatkins

2 ай бұрын

Thank you! Will do!

Does the black sand have the same properties as green sand, or is it something special?

@10swatkins

2 ай бұрын

That is something Clark would have to answer... I think they are basically the same thing. I do know that Clark makes his molding sand and it has at least 10 different ingredients.

Commenter’s like to believe they are experts

Not sure why all the hate. I guess you can’t please all the keyboard molders out there. Oh well, as long as you got it done. I enjoyed watching it. I would like to know how you prevented it blowing out on the subsequent pour(s).

@10swatkins

2 ай бұрын

I know God didn't really mean for everyone to have a keyboard... I have three more days of content from that trip.. Lots more to see :) The mold you see being made in the video had the pattern moved off center and Clark made the area where the flasks contacted each other to slope at about 20 degrees. The wood flask was not the problem. The area where the two parts of the mold touched made a "pathway" through the sand and the weight of the pour was too much for it... There is 100 pounds of metal being poured into that mold.

What is the white powder release agent between the molds?

@happycamper5213

2 ай бұрын

from what I remember from a class in college it is talc

@10swatkins

2 ай бұрын

It's not Talc for sure, that's what he told me last year. .... It's some expensive stuff that Clark swears by but I forgot just what it is...

Surely it just bigger mold time? The original was over 100 years old…how did they make it?

@10swatkins

2 ай бұрын

No bigger mold, at the limits of what you can take apart without it breaking now.... The better idea would be a smaller pattern. That core ledge makes the pattern box go to almost 30 inches to cast a 16" part. But Clark works with what he is sent. The original was made the same way this one is being made.,

The remarkable aspect about Clark isn't his lack of expertise or inadequate equipment. He's single-handedly managing a job shop, a task that's undeniably challenging and time-consuming. Had he been overseeing a production shop churning out a thousand identical items per run, the process would be expedited through permanent molds. Despite the hurdles, Clark is handling his responsibilities admirably and deserves recognition for his efforts.

@10swatkins

2 ай бұрын

I agree! Now that the process is figured out we could make enough to sink the tally Ho :) I don't think Leo would like that though.....

@davidc6510

2 ай бұрын

Well Said

Is it really only the 3:rd mold? It seems to me I've wathed a dozen videos where evertything that possibly could go wrong did. You guys must have the patience of a bunch of angels not to turn insane from spending 8 hours making a mold and then having it fail for some reason, and then having to re make it again and again. I get tired just watching the videos. Kudos for some great work.

@10swatkins

2 ай бұрын

Yep just the third one... I think there were a total of 5 maybe 6 made and 4 pours.... I was there 4 days and there were three pours... Clark is showing the abbreviated videos on his channel and he ok'ed me showing you guys what it really took in my usual really long format videos :)

Use a drilling machine to drill about 10 tiny 5 mm holes to allow air in. But before you lift the mold, use the same drill bit to clean the holes. This method improves the chances of letting air in when you lift. Also, don't pull hard; instead, just hold onto it, or use a rubber band to assist you from the top. You might even consider using a gantry. It should take about 10 to 15 minutes to free up, possibly even faster with the holes.

@10swatkins

2 ай бұрын

I suggested that but Clark with his years of experience said the vacuum was not the problem... The sharp grains of sand get forced into the pattern when ramming and it's like billions of little pins that embed themselves into the pattern. ANY little ridge or roughness serves to form a lip and prevent the pattern from releasing. Vibration is the only way to force those "pins" away from the pattern. I will show more of the problems with that pattern in the next video.. A crane would have wrecked the sand in about 2 minutes...

@FreddieMare

2 ай бұрын

@@10swatkins make total sens wit the sand like billions of little pins holding on to the pattern and I agree with your message

Well now, I sort of feel short changed that we didn't get to see all of that tap-tap-tap-tapping. Over an hour you reckon. I would have watched that. And then making the new, new mould when that one failed. I would have watched that. It occurs to me that we will get to see you men working for at lest one more video too. I will watch that, also, and be right pleased to tell my growed children how long it took. " I was clean shaved and sprightly when we began..."

@10swatkins

2 ай бұрын

There is three more days of video in my computer! IF people will watch I'll spend the hours putting it together. The next mold took two hours of patient vibrating to release .....

@davidc6510

2 ай бұрын

@@10swatkins The fast forward and squeaky mouse talk was amusing. Plus your comments - I think you get the idea. :)

Did you get a good casting since this was made?

@10swatkins

2 ай бұрын

In every video I mention we did... Must have missed that part :)

My god why people just don’t ask how something is made

@10swatkins

2 ай бұрын

That's what I keep asking Musk.... Why don't you just ask all the real rocket ship companies how to do it... After all they build 20 billion dollar rockets that only have to fly one time.... You guys built hopper out in the sand dunes with a water tower company doing the work! MY GOD what were you thinking!! AND when are going to stop blowing up so called rocket ships and get some real help! You're the richest guy on the planet, you can afford it! Damn, the nerve of some people!

28:16 Cast Iron...?? I thought it was made of bronze - No ?

@10swatkins

2 ай бұрын

Nope, Cast Iron....

Hey can you do me a huge favor? What size pants does clark wear? Im gonna buy him a new pair. Im not joking.

@10swatkins

2 ай бұрын

Josie his wife patches them up for him... Lot of love there :) I would probably be running around with no pants at all :)

@oldfarthacks

2 ай бұрын

@@10swatkins Let's not go there shall we!

@davidc6510

2 ай бұрын

@@10swatkins Good thing you know how to blur certain things on the published video :p

@davidc6510

2 ай бұрын

I was amused by the duct tape patches as well. A classic working set sacrificial battered shop duds.

lol great trolling!!

@10swatkins

2 ай бұрын

How so?

Why have you chosen to pixel blur part of the equipment?

@10swatkins

2 ай бұрын

I guess you missed the whole three minutes of explanation where I took the time to explain just that...

@MrHalukbilgin

2 ай бұрын

@@10swatkins Yep , ound it, thanks, 07:54 to 9:54... btw ,kudos to Mr Clark

just curious how thick is the sand suppose to be between the wood and iron? y'all had a bear of a job there. i don't envy you your task ahead.

@10swatkins

2 ай бұрын

Clark told me once that 4 inches was the minimum .. When I showed up with flasks that met that requirement they were quickly cut in half ;) Most of the sides of the pattern were really 5 inches away from the wood. the cores took up a lot of space and it was deceiving.

IF THEY KEEP BLOWING OUT YOU MAY NEED TO MAKE A WIDER CASTING FOR IT...

@10swatkins

2 ай бұрын

The next mold took care of the problem..

@DRNewcomb

2 ай бұрын

Wider would have been heavier. It was at the limit as it was.

I wonder how many tries it took the original foundry to produce a final casting.

@10swatkins

2 ай бұрын

We will never know.... 4 pours for us but now the process is figured out it will be a piece of cake for any more...

@flyerphil7708

2 ай бұрын

Right first time I would say.

Suppose at some distant past it was the rocket science of its time

@10swatkins

2 ай бұрын

Oh yes.... There are tons of casting videos on KZread now days and anyone can be an expert just by watching :)

Hi - I like your videos but I would like to request making a more condensed version.

@10swatkins

2 ай бұрын

Sorry, ain't going to happen :) I have just as many people yell at me for making condensed ones too... :( In fact I have made a total of 8 shorts out of 450 videos... The emails I got for making the last short just astounded me. May I suggest 1.25 or faster replay speed.... OR, do as I do, have two monitors going..... Thanks for watching

the original was made over `50 years ago, without the modern technology, and as part of a continual production line. what did they do differently..................

@10swatkins

2 ай бұрын

Not a damn thing :)

@flyerphil7708

2 ай бұрын

Knew what they were doing

@billb3444

2 ай бұрын

If that is Tally Ho’s original then it was built before 1910. The foundry who built it was turning out hundreds, maybe thousands of these. All the winches on fishing boats, schooners and barges were all cast iron. It is amazing what UK craftsman were turning out in those days. UK was one big engineering factory. Sadly now a thing of the past. Feel for you with all the trials but great and satisfying work. Love the videos.

@flyerphil7708

2 ай бұрын

@@billb3444 there are still foundries in the UK and around the world producing this kind of work every day.

The sand needs to be fully screened and added and tamped in 1” layers. When you removed the capstan you can see the lumps of sand still coagulated in balls rather than a cohesive unit. Tamping fully screened layers should rectify your issue

@10swatkins

2 ай бұрын

Might help, I don't know enough to make a judgment one way or the other. After I spent a couple of hours working on the pattern the pattern released from the sand with no problems... I think it released a total 3 times after that.. Thanks for commenting..

Almost looks like you need some sort of mechanical lifting aid to handle that mold assembly, there must be quite a bit of weight there, looks really awkward.....

@10swatkins

2 ай бұрын

Yep it's about 300 to 400 pounds... There is a hoist above us but we really have to be careful and not jar it. Next video shows it being used .....

At my age time is limited, so I watch most videos with long winded talkers at 1.25 or 1.5 speed, unless there's music, then I mute it and watch it a X's 2. 🤣🤣🤣

Nice lathe, keep talking, I'm listening. I'm old too.

@10swatkins

2 ай бұрын

Thanks 👍

I've watched several of these videos now. Do these guys know what they are doing? Because it looks like the blind leading the blind.

@10swatkins

2 ай бұрын

All I can is yes they know what they are doing. You need to understand the basic problems of making anything, out of any material, for the first time requires trial and error. The process is the same , you run into problems and you figure out a way around them... Using your logic Leo should stop building Tally Ho and find a competent boat builder because they just took 4 times to fit the bowsprit! That's not how any of this works.

I always wonder about these people that don't know the difference between production and custom. custom is expensive for a reason.

This a very labor intense mold with means expensive.A gantry crane would be nice

@10swatkins

2 ай бұрын

There was one over our heads :) Sometimes you just can't rush things I learned...