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Norm's 2 stroke repair center Having problems with your 2 stroke engine? Just ask Norm, he loves to tinker and troubleshoot engines

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  #1  
Old 03-17-2010, 09:53 AM
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Norman Norman is offline
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Default Casting Metals

Any of you guys casting your own parts? What is your green sand mix? What type of furnace you using? what you using for fuel?
How successful have you been?
I did some casting with my Dad when I was a kid and also in high school. Back in the day it was common to make your own parts by casting. I wish I'd kept all of my Dad's and Granddad's sand casting tools now.
Now I'll have to build a furnace probably charcoal fired and forced air feed.
make a batch of green sand
crucible to hold the metal in for melting and lifting tools for pouring the metal
and a flask,sand ramming tools, sand box, sifters, the list goes on and on.
If you've ever poured metal its a hoot to do.
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  #2  
Old 03-17-2010, 10:36 AM
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aspireonescs aspireonescs is offline
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Default Re: Casting Metals

been planning on doing this myself, i was thinking about a propane furnace. youtube has alot of sand casting videos, have to read/watch up it before i go and take the plunge
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Old 03-25-2010, 09:36 AM
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Norman Norman is offline
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Default Re: Casting Metals

Here's the latest on the sand casting project.
I've made the sand mixture of silica sand and bentonite clay. Mixed 10 lbs. of sand to 1 lb. of clay. The clay was powered , sand sifted to remove and trash etc.
I made the cope and drag for ramming up patterns in out of some scrap lumber. The flask measures about 8" by 10". Also 2 backing boards.
I then build 2 steel crucibles out of steel tubing about 4" in dia by 6" tall. Made the lifting tongs
dross skinner and assorted tools. Made a ingot tray out of angle iron to pour aluminum into.
I broke up about 6 briggs engines that were for the go kart. I went on an aluminum hunt and ended up with a 5 gal. bucket full.
I then proceeded to make a crude furnace out of bricks I used 3 bags of charcoal to melt about 15 lbs of aluminum into ingots. I'm now going to build me a real furnace and try used oil to fire it
The charcoal was dirty, nasty work I now have less hair on my arms, I wore myself out melting the aluminum. I had fun.
I ordered the Gingery books to make a lathe, metal shaper, and a mill they should be here today or Fri.
I jumped into to project with both feet and will be soon casting something. I did do a quick and dirty casting of a aluminum rod by stabbing a length of tubing into the bucket of sand, pulled it out and filled it with melted aluminum.
Last night a rammed up 2 heads for the china engine in the sand just to see if I could make a mold of the heads they came out good enough I could of poured them if I'd had the metal melted. So there is a way to make a modified head if a guy want to. Or any other part of these engines that is aluminum.
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Old 03-25-2010, 10:20 AM
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Ilikeabikea Ilikeabikea is offline
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Default Re: Casting Metals

I got to get over and look at your setup. You always amaze me Norm.............
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Old 03-25-2010, 06:16 PM
ZRTMWA ZRTMWA is offline
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Default Re: Casting Metals

Seems like it would be good for molding your own sprockets although I know absolutely zilch about sand casting
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Old 03-26-2010, 11:05 AM
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Norman Norman is offline
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Default Re: Casting Metals

just get the Dave Gingery books 1 to 7 the books will get you going. Or look on the net there is tons of stuff from making your own green sand to making the furnace to melt aluminum.
The Gingery books will tell you how to make a charcoal furnace to melt aluminum. Then you learn how to take that knowledge to make your own metal lathe,metal mill, metal shaper, drill press,dividing head to machine gears if you have more time than money these books are good.
You will with a lot of work will end up with a machine shop filled with machines you built yourself
if you can drill a hole, use a metal file, hack saw. All of these machines are made with hand tools

Lot of the ways these machines are made is a lost art but its been done by many if you don't have the money and want these tools then make them. heck I broke a part on my metal lathe a while back its a sears brand atlas lathe the cost to replace the broken part was over $100.00. If I'd made the darn lathe in the first place then I'd be able to just make another part to replace the broken part from melted aluminum the cost would be only in my time and the price of the fuel to melt the metal. I hope to get Ilikeabikea interested I need to make a waste oil fired furnace
then the cost will be very low.
I'm working on making the furnace out of a big popcorn can. I'll make the lining for it out of refractory cement. build the furnace stand out of rebar or conduit.
Did you know you can melt aluminum in a simple coffee can or any tin can!?The answer is yes.
Aluminum scrap metal is every where so your supply of metal is limitless.
Well what you waiting for guys make your own tools and you can make your own china engine.
Just the way you want it.
I did build my own airplane from plans, it been going for over 30 years now. So I think I should be able to make these tools.

Last edited by Norman; 07-03-2010 at 03:35 PM.
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  #7  
Old 03-26-2010, 11:25 AM
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TerrontheSnake TerrontheSnake is offline
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Default Re: Casting Metals

LoL, it is so awesome that you have brought this up Norm! I am making a gingery foundry also as well as a tunnel furnace. I am using the bottom half of a large oil barrel, refractory cement and will also be building a pour stand for my foundry. I want to do an aluminum block with cast iron sleeve top end for the china motor. Its funny how I've been gone for so long but as I come back everyone is trying the same stuff I am...great minds really do think alike!
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Old 03-26-2010, 12:12 PM
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sudjim sudjim is offline
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Default Re: Casting Metals

Hi everyone,
I have been mixing (mulling) my own green sand from regular sand from Lowes, used for mixing with cement. I was taking KITTY LITTER and grinding it down to a powder with a coffee grinder. 8 to 1 as far as a ratio to the sand (By volume, not weight) It is cheap but works poorly. I suggest going out and get some petrobond. It is oil based, not water based and holds up much better. You will get no fallout, and the detail is well worth the price.

I use a graphite clay crucible (#6 works best) The size works best for the furnaces I have built. I either use the large popcorn tins and a clay flower pot as a liner. Lowes or Home Depot sell a small steel can that worksw very well for the purpose. My last furnace lasted over a year of regular melts.

POBOYS is a seller on ebay that sometins sells blacksmith tools. He fashioned me a set of crucible tongs that was about 27" long that I still use. Was about $40, I think.

I keep my aluminum segregated. When I get a part like a piston or engine body, I melt that separate from extruded aluminum, like cans. Cans make shiny molds , pistons make strong, dull molds.

I use charcoal, but will move up to propane. I guess I'm waiting for motivation. I bought a small squirrel cage blower to power my furnace. Works well for what I do.

As for casting my own parts, I have only done some decorative stuff so far, since I do not have access to good machinery now. I have the Gingery books on PDF format, and if I had the time and enough money to quit my job, I'd tinker, build, and fabricate all day long.

If you want to be successful as a newbie, I suggest good sand, a good supply of quality aluminum, and lots of time to fire up the furnace. It is one of the most rewarding feelings, peeling back the slag on the top of the crucible and seeing pure silver liquid ready to pour.

Jim
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Old 03-26-2010, 12:17 PM
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sudjim sudjim is offline
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Default Re: Casting Metals

Oh yeah, cast iron buscuit try is my ingot mold. And pour aluminum down an ant hole, you get nice sculptures.

Can't wait to make a custom clutch cover ( and a helmet form fitted to my head )
Jim
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  #10  
Old 03-26-2010, 01:16 PM
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TerrontheSnake TerrontheSnake is offline
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Default Re: Casting Metals

LoL, metal in ant holes, thats great I just watched this documentary where they poured 10 tons of cement into a large anthill in africa. It is freakishly beautiful, and almost scary how smart ants can actually be.
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