Building a Metal Melting Furnace, Casting Marine Bronze S2-E53
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- Опубликовано: 2 окт 2024
- In this episode of The Art of boat Building (S2-E53) boat builder, Bob Emser begins the process of preparing to cast marine bronze parts for his Haven 12 1/2. The plans of the Joel White designed daysailer show plans for all of the hardware and rigging part to be cast in bronze. In this Part One of the casting series, Bob builds a small metal melting furnace the bronze. The propane furnace will fit a #6-8kg crucible.
“If you’re going to make it, make it beautiful.”
Bob Emser
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Almost anybody else would have gone to a foundry to order the parts made or try to source them elsewhere. You are a true master craftsman.
Easier said than done the EPA shut down most of the smaller foundries.
Must be nice to have had that heavy duty base on hand to make the furnace out of. It sure looks like it should stand the test of time for casting small boat parts, again and again. Don't forget a coin of significance for under the mast, even if you design and cast your own coin😉.
Excellent video sir. Recognizing that the disclaimer at the intro was necessary, this is a perfect tutorial on building a small casting furnace. Your skills continue to amaze. Thank you and looking forward to seeing you make the tools to match this small furnace. BTW, the boat looks fantastic.
Amazing. You seem to be unflabbable! Thank you for sharing!
That boat is so beautiful!
I've been involved with wooden boats for longer than I wish to admit, but this stage of casting is entirely new to me and I thank you for your efforts in communicating your knowledge. Well done!
You made all that fabricating look so easy, Bob. You're a man of many talents.
It gets better and better. Love all the details and how you go about doing everything. Thank you.
Wow ... and then Bob created a furnace for melting metal. Nice work and thanks for sharing!
Looks like quite the chore to get that refractory cement in that seam. You did a great job on that furnace Bob...looks good.
Truly fascinating. Thank you Bob. I have been looking forward to seeing this for months. Can’t wait to see the next episode.
So you are not only a woodworker/boat builder but a blacksmith, a foundry man, pattern maker, and no telling what else in order to complete this boat. Did I forget sail maker?. I expect there will be a machinist in here somewhere too. To say I am impressed would be a gross understatement. And so far it doesn't look like you are an amateur at any of those skills either. Thank you for sharing. Have a great day and stay safe.
You left out professor...🤔.
I've been looking into making my own furnace and your video is one of the best I've watched. Thanks. (Subbed too).
Thanks for the sub! Glad you enjoyed it.
Cheers,
Bob
'now we are on to the mast and rigging so what I need to do first is build a small foundry.' Bob you are amazing.. I also love the way the various bits and pieces left over from your sculptures take on a new life.
Yeah No sweat!
I know, right? Like who has a 3/8 wall 14" steel tube 5 feet long with a mounting base on one end and capped on the other just laying around? Dude has got a dream scrap pile compared to most of us, I guess.
I have no intention of building a boat but the reason I watch your show after being a builder for forty years is I still enjoy learning , thanks for posting.
Wow, thanks!
Very impressed. Immaculate work as I have come to expect from you. But I had no idea you had all those foundry skills. 🙂
You did say you would be casting the bronze parts. But I did not expect a series on building a foundry.
I was in anticipation of the casting. Now I’m stoked.
Beautiful...rr Normandy, Fra.
Great work, I enjoyed watching this.
This will be an interesting series, I look forward to the next episodes! TY for sharing your expertise.
Fantastic work, Bob! It looks great! 😃
I want to build a small forge for myself, but nothing even close to this! 😂
Anyway, stay safe there with your family! 🖖😊
Are you going to show the process of baking out your refractory, as an industrial inspector I know that this is a crucial step in keeping the integrity of your castable refractory
Hi Bob thanks for this it’s really interesting and enjoyable to watch.
' Now that we have a boat that can travel great distances, we need to power it when no wind is present. For that we will be building a Small Hadron Collider using ultrahigh vacuum and superconducting electromagnets made out of everyday supplies found at your local home improvement store.'
Ha ha ha, good luck. Just please don't let the field collapse and create a black hole that ends up swallowing the earth and everything in the vicinity. I'd like for my grandchildren to have a chance to grow up. And my great grandchild, he is only 16 months at this point.
...and very interesting...
I’ve really enjoyed your series.
I just want to encourage you and say job well done😊
Had a feeling you had some teaching experience by your demeanor. Looking forward to the foundry tools and casting episodes.
That was fascinating. Beautiful job, can’t wait to see how you make all those parts.
Excellent video Bob, thank you.
Thanks Bob, very interesting!
Nice work as always. I appreciate your craftmanship/art, and also you making these videos
Been looking forward to this section.
Thankyou again for sharing.
Great job man!! Love your tool making videos!! Great stuff!! Keep up the good work!
Another outstanding video Bob. Looking forward to watching you cast the fittings
You are a freakishly knowledgeable and skilled man. Thanks for sharing.
I really admire your skill and methods to perform the various tasks in the fabrication processes!
I looked for a link to the burner sale. But even without it, that's a beautiful furnace! Thanks!!
Inspiring, impressive stuff. Maybe tuck that shirt in when you're using a cutting wheel.
It has been a moment since your last video...I was getting a bit worried...good to see all is well! The furnace build was interesting, I am now looking forward to the tool construction.
I am sorry to have missed meeting you and checking out your boat in Mystic...Henri kinda got in the way of that...but your boat is beautiful!
Dear Bob! Thanks for showing who you are building your furnace! It is highly professional. Thanks!
My pleasure!
As always I really enjoy this channel. However, when we start off with an English lesson; I just love it!
Is there a burn in period for the forge and cruciable before you add any bronze?
Most high heat cements do have a cooking cycle to go through before taking them to forging or foundering temperatures, a curing process, if you will. Always read the manufacturer's instructions on the bag or website.
Did the fire proof insulation end up being smashed against the inside wall of the steel tube, possibly losing some of its efficiency? Could a larger tube have been used in addition to the smaller one during the pour to make the concrete hold its tubular shape and then removed after allowing the insulation to then be added after?
Hi Bob, Wonderful content and superb editing as usual, too. I had half a thought as to trying to cast my own bronze and after watching this, I"m even more glad that I left it to a pro. That said, I have no doubt that YOU can do your own. I can't wait to see the next steps and how you do the actual individual molds. Cheers, Chuck
Thanks Chuck!
Maybe you'll get to this, but is there a way to melt down your old silicon bronze screws and get marine bronze again? Do you need to add zinc? Thanks!
Yes, I will be able to melt silicon bronze scrap. No need to add other alloys.
Thanks for watching,
Cheers,
Bob
Beautiful piece of work :-)
Lovely start to an interesting series. Need to cast bronze. Step 1: create foundry (no surprise there!). Looking forward to next videos in the series. Especially (way down the line) when you make the wooden patterns and cast the parts.
Umm, furnace... foundry is the collection of many tools, which we will get to more of in the next video, evidently. This guy is college level teaching us boat building with side courses in tool making and foundry making to make your own parts too. I am so glad I found this channel a couple of years ago.
I do kind of wish he had taught us to build the burner though.
Super interesting. It looked like that dry mix cement was not the easiest getting it into that small gap.
Coming in a bit late; what size burning did you pick? Looks like they have an 80K and a 180,000btu.
Hi Jon,
It is the 180,000btu burner.
Thanks for watching!
Bob
Hi Bob. I just started to watch your boat building videos, and I have to say you are a man of many skills. I am enjoying watching you at work. I have some masonry skill and wonder what you think of the idea (this came to me while watching you create the furnace) of using a chimney thimble inside the furnace instead of the cylindrical concrete form then maybe using a 2” thick outer sheet eliminating the need for the refractory cement, probably a little easier and quicker process?
Hi Jim, That a good idea. In what inch increment do they come in?
Thanks for your kind words, and thanks for watching!
Cheers,
Bob
thanks for posting.
Great job!! Love it!
where you added the burner, do you need to seal the gap where the thumb screws are?
Yes, I lightly pack some ceramic fiber that I had use to line the furnace.
Well done!
Thank you very interesting video👍👍👍 be careful when working with ceramic fibre. Fiber dust is Bad for lung. Greetings from Germany
I love this channel! Great job!
Glad you enjoy it!
I concur! 😀
Hi Bob. The level of professionalism and craftsmanship you share in your videos is extraordinary. I enjoy watching your video immensely and hope to see more ambitious projects in the future. 👏👏👏
Fire it Bob.
Your videos are a class act... 2 questions if you have opinions.
> Do you have a trusted recipe for refractory? (I collected Portland cement, sand, a little Perlite, a high fire clay and another containing grog to help with thermal shock). May need to find a more specialized store. Some recipes say fireclay - whatever that is. Some think perlite melts or flux it to melt at lower temp, or is too soft.
> Is forced air just more fuel efficient or hotter, gather it may be needed for a natural gas or an oil burner? (I bought a Devils Forge Venturi burner & regulator - looks & test burns nice, a good move).
I have cut a 12" OD air tank to size, made a sand box, Now planning the insulation, drying & tongs steps.
In a class in Brooklin ME we used insulated 5 gal paint can furnaces with forced air and a lift off lid. Warnings I remember were use outside (CO hazard), preheat/dry metal to dry, we put down plywood so hot metal couldn't directly hit damp gravel floor of pole barn, wear some leather and long cotton, face shield(?).
Thanks again for your video series!
Not too late to correct your terrible mistake and turn the rest of that pipe into a deck cannon like we talked about on Insta! Excited to see part 2 with the tools I was wondering how you were going to get that crucible out. Really interesting video never would have thought to cast my own bronze hardware
too cool
That was excellent. I have had multiple careers, 9 years of art and quite extensive woodworking and metal working on mills and lathes. But i think your classes would have been a feather in my cap as it is always great to learn new and exciting techniques and trades. Your videos are a great learning source and sure spark an intrest in people who only dreamed of doing things with their hands.
Cheers.
Your skill level is awesome!
Is there any chance that air trapped in the cement mix will cause the whole thing to explode, when heated to high temperature, or will ramming it in with a stick prevent all that?
There is always a chance. But mixing it well to help prevent overly wet spots, and packing it as best as possible will reduce that risk as much as humanly possible. Also, that 3/8 inch steel wall should help to contain it, along with the cusion from the kayowool, and the top amd bottom vent holes and the fact that the lid doesn't seal or lock. It is not going to build pressure like a sealed pressure cooker.
Intresting and a lot of educations ! 🙂
Masterful craftsmanship.
Vary creative.👍🏻👍🏻👍🏻
Wow very nice work
Love your work
very informative