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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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  #11  
Old 03-26-2010, 04:46 PM
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sudjim sudjim is offline
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Default Re: Casting Metals

Here's a couple shots of my first furnace and then my second one.
Notice the first used a hair dryer and i gutted the heating element and ran it off a 12v battery charger at 2 amps. Let me know if I can answer any questions on building or melting. I am by NO MEANS an expert, but I have been messing around for about 8 years or so doing this.
Jim
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  #12  
Old 03-26-2010, 10:54 PM
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Norman Norman is offline
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Default Re: Casting Metals

Looks like you guys like to do some of the same things I like!
Hey today I started on making the furnace. I'm using a large popcorn can. I bought some refracroty cement,perlite,portland cement,fire bricks,and more playsand.
I've lined the bottom of the can with a mix of refactory cement mixed with perlite, sifted play sand,portlandcenemt. The mix is with very little water,I rammed it in place about 2" deep, made a 1 1/8" drain hole in the middle. Next will be the fire brick for the walls.
The bricks are easy to cut with a hack saw so I should get a nice tight fitting wall. I have some srainless steel sheet metal I might line the furnace with to protect the brick I want to use waste oil for fuel. I'm afraid the extreme heat will eat the bricks so the thin stainless steel sheet might help protect the brick at least where the main part of the flame jet will hit it.
I made the top of the furnace with a mix like in the bottom and about 3" thick with a 4" hole in the center. I ran coat hanger wire through the lid for poorboy rebar.
Welded on some home made handles on both the lid and the main body.
I'll have to take some photos if I can stop long enough, just been to busy.
I want to be able to raise the lid with a foot lever and be able to swing it out of the way so I'll start working on that soon. For me its been fun so far.
When I was a kid my Dad made a complete electric motor reminding machine by casting the parts in aluminum in our basement we had a stoker coal furnace for heating the house . Dad also used the house's furnace for melting the aluminum. I was his helper I made all of the sand cores for his molds. I was around 12 years old I got a good education on sand casting from my Dad. I learned about every cuss word in the book and some ones that weren't in the book from Dad when a pour went south or a mold dropped out. I also was the muller for the sand did it all by hand.
My Mom sold our house about 10 years ago all of the casting stuff was still there in the basement, it went with the house I wish I'd taken it when she offered me all that casting stuff. If I would have the only thing I would need is a furnace. I didn't ever plan to casting anything again.

Last edited by Norman; 03-26-2010 at 11:16 PM.
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  #13  
Old 03-27-2010, 06:06 PM
ZRTMWA ZRTMWA is offline
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Default Re: Casting Metals

Quote:
Originally Posted by TerrontheSnake View Post
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.
That was too sick!!!

YouTube - Worlds Biggest Ant Hill AMAZING
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  #14  
Old 03-28-2010, 09:04 PM
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Ilikeabikea Ilikeabikea is offline
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Default Re: Casting Metals

Here's Norms furnace.

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  #15  
Old 03-29-2010, 06:41 AM
Fabian Fabian is offline
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Default Re: Casting Metals

Hi Norm

Great to see this threads progression.

What are the chances of casting a newly designed cylinder, but copied of the original HT style cylinder porting configuration and making it a "big bore" at 60mm.
You could then use a Husqvarna 3120 piston for an engine capacity of close to 115cc.

Fabian
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  #16  
Old 03-29-2010, 09:11 AM
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Norman Norman is offline
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Default Re: Casting Metals

It could be done the mold would take a bunch of time to figure out and make.
I don't think I'd want to try it.
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  #17  
Old 03-30-2010, 01:53 PM
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sudjim sudjim is offline
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Default Re: Casting Metals

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Originally Posted by Norman View Post
It could be done the mold would take a bunch of time to figure out and make.
I don't think I'd want to try it.
I agree. You would have to make the cyllinder, and make a core where the hole is and all the passages. I have never done a casting with a core. I wonder how they cast it at the factory. If we could get our hands on their mold with cores, I bet they could be cleaned up. I may tear down a cylinder to see what is steel, and how it is pressed or attached to the aluminum.
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  #18  
Old 03-31-2010, 10:11 PM
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Default Re: Casting Metals

I test ran the furnace today. I burned 2 gallons of oil made a mess, burned a hole in the drive way, burned the wheels of the furnace cart.
Part of the lids insulation came off. When the thing did run it sounded like a jet. Got hotter than
4ell then as it was going good I put in a little more oil in the fuel tank, didn't know the oil had water in it to make a long story short the fire went out. I cleaned up the mess patched the hole in the concrete repaired the furnace. Now I'll let it set until next week. I plugged the drain hole in the furnace bottom. The hole has there in case the melting pot leaked, instead it would leak oil and set the small wheels on fire,I planned to make some steel wheel now I have to.
I'll need to get some more waste oil and try it again.
It will melt aluminum fast if I didn't have the drain letting oil out the bottom setting the world on fire and blowing a hole in the driveway.
Did I say fire is cool? When its burning right there is no smoke. Just some noise and lots of heat
this would have been a good winter project.
It reminded me of working on the oil rig when the well blew out and caught fire,except here there was no screaming or cussing.
More to come.
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  #19  
Old 04-08-2010, 11:05 PM
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Norman Norman is offline
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Default Re: Casting Metals

I've been making patterns for the Dave Gingery metal shaper. Been pretty busy up making them.
I've got the ram part made today. I made the frame parts yesterday. Lot of wood patterns to make then cast.
I could even start casting and have the main frame done if I can get the castings to turn out good
that will be the tough part. I'll have to post some photos of what I've been up to.
Ilikeabikea took some photos of me ramming up a cylinder head but he hasn't put them on here so maybe he will sooner or later, I did the head pattern just for fun and practice and to show Bob how its done.
Norman
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  #20  
Old 04-09-2010, 06:05 PM
Scotchmo Scotchmo is offline
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Default Re: Casting Metals

Wood patterns are good for limited production. If you just need one item out of aluminum, you can make an expendable pattern out of Styrofoam. No need for cores, draft or cope and drag. I built a gearbox in college (30 years ago) and made the case in the school foundry. The pattern was made of Styrofoam glued together with white glue. Fill it with sand and bury it. Use a Styrofoam sprue and riser or some thin wall metal tubes poked into the Styrofoam that you can pull out before you pour. The molten aluminum vaporizes the Styrofoam and leaves the metal copy in itís place. Allow about 3% in the pattern for shrinkage. Do in a well ventilated area as the Styrofoam vapor is bad.

The lost foam process was not that common back then but is now widely used to make complex engine blocks and other components.

On a side note. I recently located the remains of that gearbox and the mini-baja car that it was used on. It was missing a lot and overgrown with weeds in the backyard of someone living about 20 miles from me. My brother actually found it after a conversation with a co-worker. It was my senior project in college. I am going to attempt to resurrect it. I dug out some old pictures.

The first picture is of the completed gearbox and the other two are from the competition. It was sponsored by the SAE and held at Cal Poly Pomona that year. We were from Cal Poly San Luis Obispo. These collegiate mini-Baja competitions are still held today throughout the world.
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