Really beautiful work. You've sorted out answers to a lot of problems along the way, it's kind of you to share that knowledge with everyone. Love the solution for foam CNC dust collection!
Thanks for mentioning the soapy water step! I was spending a lot of time with my molds having to brush out air bubbles and seemed to be a never ending battle. Awesome explanations!
It blows my mind that you dont need a vent in lost foam casting! It burns up so completely, but I would have still thought you would get air pockets that would stop the aluminum from flowing into tight spaces, I made some lost wax investment castings years ago for filling up the ex. port floor on cleveland style heads, LOVE seeing your videos making long obsolete really cool BOSS parts!
Very Nice work, Kelly. It's good of you to post these videos to help others who might be interested to do something similar. Always lots information shared in each video. All the Very Best for Christmas too 🙂👍
Nice to see you again, any day now my 3018 cnc rotor/engraver will arrive, i have my beer keg foundry started, i'm going to start out simple and cast some carb mounts to turn single carb ford flathead intakes into three carb intakes, a friend has about 50 single carb intakes, then i want upgrade the rotor to do flathead heads, looking forward to more of your videos.
You're ahead of the game if you're starting out with CNC'd patterns.....your castings are never better than your patterns so good patterns are key. I really like my CNC router. I'm going to modify it for more Z axis travel. I have a buddy that's into Flattys too....simple engines but fun and were big deal when they were ontroduced. Take care, Kelly
I would love to know how much money it costs for the customer . You do amazing work . I am thinking 10k to 15k . You can't go buy that stuff off the shelf . I would think any part would be times 10x to 15x percent of the cost of something close to production parts price .
After you register, you have to be approved. That's usually done within a few hours but there's just two of us that process them so with international time differences, maybe a day at worst. After approval, you can post and have full visibility of content. Best, Kelly
Maybe you could use a thermal camera to see the difference in flow speed with the different foam types,. Make a thin rectangle container for the sand, if nothing is learned, atleast it would be a cool video!!
I am quite interested in this method of making aluminum parts, so I have 2 questions, if someone feels like chiming in. First, this appears to be a hybrid of investment casting and sand casting. I would normally expect a truly investment cast part would have quite a thick layer of slurry/sand, slurry/sand, etc., until it builds up a thick and strong coating of the pattern. So is this literally 1 dip, and then supported by sand in the barrel, to take the place of all the additional slurry/sand layers ? Second, with lost foam casting, does the molten aluminum burn out the foam as it's being poured into the mold ? Is there no burnout of the pattern before the metal pouring ? Thank you, Tom.
Yes, the foam pattern remains in the mold and is evaporated as the molten metal is poured and advances. Yes, it is one dip, but the thin coating provides little to no structural support to the mold. The purpose of the (permeable) refractory coating is to control the rate at which the evaporated pattern gases escape and thus speed at which the molten metal advances. There is no binder in the dry sand mold but with vibratory packing, it is much more tightly bound than loose sand. The hydrostatic pressure of the molten metal helps hold the sand in place. Like other evaporative pattern casting processes, there is no need for draft, complex parting lines, cores, or pattern tooling, but you must make an expendable foam pattern for every casting. The primary advantages of lost foam casting compared to other evaporative pattern methods (lost wax or PLA shell or investment casting) is it requires no burn out step and enjoys very low pattern and mold costs. Best, Kelly
Over night but small simple patterns could be 5-6 hours. In the Winter, the bathroom in my shop has a heat delivery duct. If I close the door, it's a perfect drying room. In the summer, ambient produces the same result. A gentle breeze accelerates drying. Sometimes you need to move air through deep cores and passages or they could takeseveral days without but that's not the norm. Best, Kelly
I restore Inline carbs, sell and make replacement and custom related parts, including complete turnkey induction systems. I’m an admin at a hobby casting forum so most of my content is casting how-to stuff. If you poke around my channel you’ll see other Inline carb parts………. www.inlinecarb.com Best, Kelly
Absolutely M.A.G.I.C.A.L. A work of Gear Head Art (GHA).i wish I had 10% of your energy "to get things done"... I loved the use of a "flexible" round element to fit the long-oval. Never crossed my mind. I'd still be hunting for that exact element 8O\ DaZzLed and impressed. Thank you. Cheers!
Glad to see you back doing your casting videos. Your work is educational and exceptional.
This engineer is impressed by your professional setup and casting quality. Nice work man!
Really beautiful work. You've sorted out answers to a lot of problems along the way, it's kind of you to share that knowledge with everyone. Love the solution for foam CNC dust collection!
Thanks for mentioning the soapy water step! I was spending a lot of time with my molds having to brush out air bubbles and seemed to be a never ending battle. Awesome explanations!
What a great use of the CNC router! Gonna have to try this myself!
Great to see you posting. Love your videos. Haven't really found anyone else that shows these professional results.
Thanks bud. I give it my best. K
It blows my mind that you dont need a vent in lost foam casting! It burns up so completely, but I would have still thought you would get air pockets that would stop the aluminum from flowing into tight spaces, I made some lost wax investment castings years ago for filling up the ex. port floor on cleveland style heads, LOVE seeing your videos making long obsolete really cool BOSS parts!
Yuo sure know what you are doing, a pleasure to watch the quality products that you are making.
Great stuff Kelly. Was getting worried that you had stopped making videos. Thoroughly enjoy all of your stuff. Regards Greg
Just busy with life and the seasons, but Winter time means shop time! Best, Kelly
Just started the watch your series and all I can say is thank you
Yeah I was a bit worried so look forward to watching your vids and nothing in 4 months. Good to see ya back on, these vids are awesome!
Good to see you are still doing amazing things with your skill set, Kelly. ……👍✌️❤️
Brilliant as always... Martin
Very Nice work, Kelly.
It's good of you to post these videos to help others who might be interested to do something similar.
Always lots information shared in each video.
All the Very Best for Christmas too 🙂👍
Glad to see you back on the channel
Nice to see you again, any day now my 3018 cnc rotor/engraver will arrive, i have my beer keg foundry started, i'm going to start out simple and cast some carb mounts to turn single carb ford flathead intakes into three carb intakes, a friend has about 50 single carb intakes, then i want upgrade the rotor to do flathead heads, looking forward to more of your videos.
You're ahead of the game if you're starting out with CNC'd patterns.....your castings are never better than your patterns so good patterns are key. I really like my CNC router. I'm going to modify it for more Z axis travel. I have a buddy that's into Flattys too....simple engines but fun and were big deal when they were ontroduced. Take care, Kelly
Absolutely beautiful castings, your process is dialed in well.
Looks good, nice one. thanks.
Great videos
Good to see another video. Love the quality of your work. Do you use the CAD file to work out how much aluminium you need to melt?
Agora sim tá com máquina nova
Thanks for sharing and Merry Christmas to you and your family 👪
To you as well....Tis the season...Bset, K
Would love to see your 3D modeling, and tool path generation, process.
I use Alibre Design Pr for CAD and CamBam for CAM. You can go a long way with just CamBam for up to 2.5D Cad/Cam work of this sort. Best, Kelly.
I would love to know how much money it costs for the customer . You do amazing work . I am thinking 10k to 15k . You can't go buy that stuff off the shelf . I would think any part would be times 10x to 15x percent of the cost of something close to production parts price .
Just signed up to the forum only to see I'm unable to post
After you register, you have to be approved. That's usually done within a few hours but there's just two of us that process them so with international time differences, maybe a day at worst. After approval, you can post and have full visibility of content. Best, Kelly
@@kellycoffield533 Ok thanks
The stress on them that causes them to bow like that is interesting, guess not surprising, but interesting!
Maybe you could use a thermal camera to see the difference in flow speed with the different foam types,. Make a thin rectangle container for the sand, if nothing is learned, atleast it would be a cool video!!
I have actually considered this. Have gone as far as looking at lower cost (
Nice 👍
I am quite interested in this method of making aluminum parts, so I have 2 questions, if someone feels like chiming in. First, this appears to be a hybrid of investment casting and sand casting. I would normally expect a truly investment cast part would have quite a thick layer of slurry/sand, slurry/sand, etc., until it builds up a thick and strong coating of the pattern. So is this literally 1 dip, and then supported by sand in the barrel, to take the place of all the additional slurry/sand layers ? Second, with lost foam casting, does the molten aluminum burn out the foam as it's being poured into the mold ? Is there no burnout of the pattern before the metal pouring ? Thank you, Tom.
Yes, the foam pattern remains in the mold and is evaporated as the molten metal is poured and advances. Yes, it is one dip, but the thin coating provides little to no structural support to the mold. The purpose of the (permeable) refractory coating is to control the rate at which the evaporated pattern gases escape and thus speed at which the molten metal advances. There is no binder in the dry sand mold but with vibratory packing, it is much more tightly bound than loose sand. The hydrostatic pressure of the molten metal helps hold the sand in place.
Like other evaporative pattern casting processes, there is no need for draft, complex parting lines, cores, or pattern tooling, but you must make an expendable foam pattern for every casting. The primary advantages of lost foam casting compared to other evaporative pattern methods (lost wax or PLA shell or investment casting) is it requires no burn out step and enjoys very low pattern and mold costs. Best, Kelly
@@kellycoffield533 Thanks Kelly. Very helpful. Tom.
Очень круто 👍👍👍
How long do you let the patterns dry after dipping them?
Over night but small simple patterns could be 5-6 hours. In the Winter, the bathroom in my shop has a heat delivery duct. If I close the door, it's a perfect drying room. In the summer, ambient produces the same result. A gentle breeze accelerates drying. Sometimes you need to move air through deep cores and passages or they could takeseveral days without but that's not the norm. Best, Kelly
You do this as a hobby or is someone actually asking you to make these arts?😃
I restore Inline carbs, sell and make replacement and custom related parts, including complete turnkey induction systems. I’m an admin at a hobby casting forum so most of my content is casting how-to stuff. If you poke around my channel you’ll see other Inline carb parts………. www.inlinecarb.com Best, Kelly
Absolutely M.A.G.I.C.A.L. A work of Gear Head Art (GHA).i wish I had 10% of your energy "to get things done"... I loved the use of a "flexible" round element to fit the long-oval. Never crossed my mind. I'd still be hunting for that exact element 8O\ DaZzLed and impressed. Thank you. Cheers!