I already have two sub panels and have 3ph, and 1ph 240/120vac circuits and receptacles in my shop everywhere imaginable, thus the lack of panel space. I thought I had provisioned for everything imaginable.......except a 100 amp foundry furnace LoL. It was much easier and less expensive to merely make room for the furnace circuit with a low voltage tandem breaker and a couple conduit fittings rather than install yet another sub panel, but next time, if there ever is one, I'll have no choice. Best, Kelly
I remember a mold/pattern that you made for an SCBA backpack container many years ago. It was pre - CNC days and recall that it involved a long radius swing arm to cut the core. Cheers!
Hey DH, hope all is well. My DOS skills never improved and still a Windows dork, but better with CAD/CAM than I was in my engineering days. Best, Kelly
Thats one awesome setup, really impressive. Ive been watching your videos for many years and im always impressed with your work. I like the attention to detail and your good explanation of it all.
It's discussed in most of my intake manifold videos but is simple. I use A356 alloy and T5 at 445F for 8hrs because it achieves 80-90% of the improvement as T6 without risk of damage to the casting. Best, Kelly
I don't know for sure because I never used the previous furnace with NG, but I'd have to believe a well-tuned burner could easily melt twice as fast, but, I would much rather have the furnace atmosphere of a resistive electric than fuel fired furnace for controlling the aluminum melt quality. Best, Kelly
Sweet project. I wish you were my neighbor. Are you an ME or an EE? Have you ever experimented with cast iron? How do you control for purity, just make sure the scrap being melted is clean?
I do use scrap on occasion for ornamental stuff but for things that matter, I use A356 ingot. I have a self-made degassing lance, but never use it for the latter because the furnace atmosphere in resistive electric furnaces is so favorable for aluminum melting. Best, Kelly
It was Morgan pumpable refractory called Seal Coat HT. When cured, it's properties are very similar to K26 insulating fire brick. I bought it second hand from a surplus company for $30/5 gallon (I bought 4 and used 2 for the build) and was able to have a relative pick it up to avoid expensive shipping. If price were no object, I would have preferred one of Morgans pumpable/moldable ceramic fiber materials like I used on my smaller furnace, but that would have been >$500/5gal if I could even get it. So far so good. Best, Kelly
The furnace is insulated well enough that you can touch the exterior barrel/body with your hand when the furnace is at temperature. When I touch the raceway, I can barely detect it being above ambient temp. Given that, it packaged much better at the top to accommodate the loop in the moving electrical cable that connects the furnace to the top of the controller. Best, Kelly
You make us proud
Rock on
Very well done video considering the amount of time it was filmed over. As always a plethora of quality information and top-notch execution!
That's a killer upgrade, congratulations!
Amazing engineering Kelly.
Wow ! What talent you have ! Very, very nice !!!
Holy plug batman! Just got to that part in the video. Now you have my full attention!
DIY dude of the year!
Kelly, You are an incredible mix of engineer and craftsman, wish you didn't live on the other corner of our country!
Very kind words. Thank you. For me designing and building the equipment is as enjoyable as using it. Tools making tools! Best, Kelly
Hi Kelly, you can just put an adder panel to the side of your original panel off the panels busbars that way you don't have to remove any loads.
Rich
I already have two sub panels and have 3ph, and 1ph 240/120vac circuits and receptacles in my shop everywhere imaginable, thus the lack of panel space. I thought I had provisioned for everything imaginable.......except a 100 amp foundry furnace LoL. It was much easier and less expensive to merely make room for the furnace circuit with a low voltage tandem breaker and a couple conduit fittings rather than install yet another sub panel, but next time, if there ever is one, I'll have no choice. Best, Kelly
Fantastic work. Pleasure to see it come together so nicely. Thank you for sharing.
I remember a mold/pattern that you made for an SCBA backpack container many years ago. It was pre - CNC days and recall that it involved a long radius swing arm to cut the core. Cheers!
Hey DH, hope all is well. My DOS skills never improved and still a Windows dork, but better with CAD/CAM than I was in my engineering days. Best, Kelly
@@kellycoffield533 Cheers!
Thats one awesome setup, really impressive. Ive been watching your videos for many years and im always impressed with your work. I like the attention to detail and your good explanation of it all.
Awesome foundry setup.Great work.Thanks for showing us such a cool project.
I am setting up my foundry.
Made my butt pucker all the way on the west Coast 😂 great work Kelly.
😀It gets my attention too. Best, K
Awesome! What more is there to say?
Nice upgrade. Have you thought about some sort of provision for raising the cable off the ground in case of a conductive molten spill?
I think you are actually building the Death Star.
Thanks for the video, I checked your videos, did not see any on heat treatment.
It's discussed in most of my intake manifold videos but is simple. I use A356 alloy and T5 at 445F for 8hrs because it achieves 80-90% of the improvement as T6 without risk of damage to the casting. Best, Kelly
Excellent furnace. How does it compare for speed to nat gas?
I don't know for sure because I never used the previous furnace with NG, but I'd have to believe a well-tuned burner could easily melt twice as fast, but, I would much rather have the furnace atmosphere of a resistive electric than fuel fired furnace for controlling the aluminum melt quality. Best, Kelly
Would you be interested in casting some NiBrAl for Engine dyno parts?
Thanks for your interest but no. Best, Kelly
Sweet project. I wish you were my neighbor. Are you an ME or an EE? Have you ever experimented with cast iron? How do you control for purity, just make sure the scrap being melted is clean?
I do use scrap on occasion for ornamental stuff but for things that matter, I use A356 ingot. I have a self-made degassing lance, but never use it for the latter because the furnace atmosphere in resistive electric furnaces is so favorable for aluminum melting. Best, Kelly
@@kellycoffield533 Cool. Thanks for the response
Could a ceramics kiln do a similar job for amateur guys?
Yes
So what was the material you found for this, and your supplier? (if its not a secret)
It was Morgan pumpable refractory called Seal Coat HT. When cured, it's properties are very similar to K26 insulating fire brick. I bought it second hand from a surplus company for $30/5 gallon (I bought 4 and used 2 for the build) and was able to have a relative pick it up to avoid expensive shipping. If price were no object, I would have preferred one of Morgans pumpable/moldable ceramic fiber materials like I used on my smaller furnace, but that would have been >$500/5gal if I could even get it. So far so good. Best, Kelly
wouldn't it be smarter to have the plastic junction at the bottom of the raceway to keep it in the coldest spot?
The furnace is insulated well enough that you can touch the exterior barrel/body with your hand when the furnace is at temperature. When I touch the raceway, I can barely detect it being above ambient temp. Given that, it packaged much better at the top to accommodate the loop in the moving electrical cable that connects the furnace to the top of the controller. Best, Kelly
Thanks for the video, love seeing you build this!