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Metal Casting at Home Part 1 Backyard Foundry

10.22.2008
The first of many videos showing how I make aluminium castings in my home made foundry. Part one shows how the mould is made and in part two the metal is melted and poured.
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Metal Casting at Home Part 51 Oil Fired Furnace Build Part 3

03.05.2015
In this video the main part of the refractory is cast. The outside will be insulated with 50mm of ceramic fibre blanket and wrapped in a steel casing. Not shown on the video but I did fill the inside of the plastic with sand to prevent it deforming. More furnace details can be seen here http://myfordboy.blogspot.co.uk/p/d...
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Metal Casting at Home Part 2 Backyard Foundry

10.22.2008
In part one I made the sand mould. Now I melt metal and complete the casting.
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Metal Casting at Home Part 52 Oil Fired Furnace Build Part 4

03.20.2015
In this video the furnace cover is made. In the next part the final assembly will be shown. More furnace details can be seen here http://myfordboy.blogspot.co.uk/p/d...
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Metal Casting at Home Part 3. Backyard foundry

12.07.2008
How to make a greensand mould using a loose piece.
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Metal Casting at Home Part 53 Oil Fired Furnace Build Part 5

03.27.2015
The furnace is now complete. The next video in the series will show the firing up and casting. More furnace details can be seen here http://myfordboy.blogspot.co.uk/p/d...
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Metal Casting at Home Part 4 Backyard Foundry

03.30.2009
Casting parts for a model engine in aluminium .A sand core is used to make the casting hollow.
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Metal Casting at Home Part 54 Oil Fired Furnace Build Part 6 (Re uploaded)

04.15.2015
This is the final part of the furnace construction showing it in operation although there will be one more showing how the brass badge was made. The first crucible full of metal took 20 minutes from cold and subsequent ones only 10 minutes. 5 ltr of uncut used motor oil was burnt during the 90 minutes the furnace was fired. The burner nozzle was supplied with air at 15 psi. More furnace details can be seen here http://myfordboy.blogspot.co.uk/p/d...
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Metal Casting at Home Part 5 Backyard Foundry Core Making

04.13.2009
Making sand cores as used in Metal casting at Home part 1 and 4
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Metal Casting at Home Part 55 Casting a brass label/plaque/nameplate

04.30.2015
My Kasenit furnace has a nice brass label on the side. To give my home build a professional finish I have cast a similar one to add. I am using the electric furnace on it's side so a larger crucible can be used. The main function of this particular furnace is for enameling.
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Metal Casting at Home Part 6 Preparing the Moulding Sand

04.25.2009
A short video showing how the sand is prepared for use.
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Metal Casting at Home Part 56 Tool Caddy for Safe Working.

05.22.2015
When working with hot metal safety is important so tools are taken from this caddy. Stops you tripping over them when they fall on the floor. Also shown on the video is an improved latch for my crucible lifter to handle the extra weight of using a larger crucible. The noisy compressor in the video has now been replaced with a quieter belt drive model. The furnace has now melted iron, sorry no video.
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Metal Casting at Home Part 7 Oddside Mould Making

05.04.2009
Making a greensand mould when there is no flat surface to make the parting line.
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Metal Casting at Home Part 58. Brass Flywheel

06.18.2015
I thought I would try a brass casting for a changed now that I can easily melt brass in the new furnace. Liquid gold!
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Metal Casting at Home Part 8 Pattern Making

08.19.2009
Showing how wooden patterns are made to make greensand moulds.
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Metal Casting at Home Part 59 Oil Fired Furnace Operating Instructions

06.28.2015
Here are more detailed instructions showing my furnace in use. You can see how with careful design using waste motor oil is not dirty to use which was one of my concerns before doing this project. More furnace details can be seen here http://myfordboy.blogspot.co.uk/p/d... The casting shown is for my Stove fan https://www.youtube.com/watch?v=ISD... Castings and plans available for sale.
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Metal Casting at Home Part 9 The Furnace .

09.26.2009
Details of the equpment I use in my home foundry. More details including plans can be found at myfordboy.blogspot.com
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Metal Casting at Home part 60 Spoked wheel Castings

07.12.2015
Moulding these wheels is a little tricky and care has to be taken to remove the pattern without damaging it. I used some wood screw to reinforce the sand between the spokes. I have shown mould making many times so I have left out the captions on this video but if anything is not clear feel free to ask by making a comment. These castings are for sale.
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Metal Casting at Home Part 10 Another Day in my Home Foundry

10.11.2009
How to make a casting from making the sand mould to the finished item. The video has been edited to fit the 10 minute time limit of You tube. It takes much longer than this!
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Metal Casting at Home Part 62. Detailed Pattern Making. The Myfordboy Steam engine.

08.21.2015
This video shows in detail how the pattern was made for a simple model steam engine. Also shown is how a core is made to make the inside hollow and the casting of the part. The engine will run on steam or compressed air at 5 PSI or less. The concept is for good looking, easy to make engine that could be quickly made, not highly detailed but better quality than a Mamod or Wileso model. The engine is double acting and has slip eccentric valve gear so it can be run in either direction. The engine frame shown here and a flywheel casting together with plans will be available for sale if you would like to make one.
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Metal Casting at Home Part 11. Sodium Silicate & CO2 Core Making.

11.22.2009
Making sand cores for a greensand mould using Sodium Silicate and CO2 to harden the sand.
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Metal Casting at Home Part 57 The Foundryman's Lunch, Cooking with Oil

05.27.2015
It seemed a shame not to use the heat left in the furnace after a casting session, so I cooked the lunch!
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Metal Casting at Home Part 12. When Castings Go Bad

01.24.2010
Things don't always go well in the home foundry.
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Metal Casting at Home Part 61 Cutting Alloy Wheels for Casting

07.27.2015
I have tried several methods of cutting up wheels for melting and the method show I have found works best. Special thin aluminium cutting discs in an angle grinder wear out too quickly. The Evolution saw runs at a slower speed that a woodworking saw and the Evolution blade cuts the metal OK but the fine teeth clog easily and can break off when cleaned out. The blade shown has fewer teeth so there is no room for metal to clog them.
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Metal Casting at Home Part 13. Small Casting with Core.

04.26.2010
Making a small casting in aluminium. A core is used to make the intenal detail of the casting. This is the gearbox for my Stickney engine model. There are some slight differences in technique from my other videos, I am learning all the time!
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Metal Casting at Home Part 64. Casting and Machining a Toothed Pulley.

01.15.2017
The video shows how a toothed pulley was cast and then machined. The pulley is to go on my spin indexer which will be connected with a toothed belt drive to an Arduino controlled stepper motor. This will enable any number of divisions to be indexed at the touch of a button. The electronics and Arduino sketch were devised by Gary liming and can be seen here. http://liming.org/millindex/ Details were also given in Model Engineers workshop issue 249. Arduino and LCD shield https://goo.gl/s7R4Zz Motor driver https://goo.gl/Fh72ie Stepper motor https://goo.gl/8khVSQ
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Metal Casting at Home Part 14 Another Flywheel Casting

06.13.2010
Casting a pair of flywheels for my model Stickney engine. They will be lead filled and fitted with steel rims.
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Metal Casting at Home Part 65. Casting and Machining a Tee Slot Table.

03.18.2017
Continuing my conversion of the Banggood engraving machine. Here I make a tee slotted table cast in zinc/aluminium which will give a hard wearing table. This will replace the extruded table and will be fitted with 12mm rails instead of the 8mm ones. Details of the conversion http://myfordboy.blogspot.co.uk/p/b... Link to the engraving machine https://goo.gl/CVZs2i 500w spindle https://goo.gl/zkMmgD Special offers on other CNC parts: https://goo.gl/rjNzpb Bromsgrove greensand and ZL12 ingots from http://artisanfoundry.co.uk Construction of the furnace starts here https://youtu.be/ZbnroanPt4g
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Metal Casting at Home Part 15. Pattern making, start to finish.

09.03.2010
Full details of making a wooden pattern for a greensand mould. Part 16 will show the casting being poured.
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Metal Casting at Home Part 66 One Part Pattern with Detail on Both Sides.

03.28.2017
The video shows the pattern making, casting and machining of a replacement part for my Banggood engraver to CNC mill conversion. Further details of the conversion can be seen beginning here https://www.youtube.com/watch?v=kRf... and on my blog http://myfordboy.blogspot.co.uk/p/b... Banggood CNC engraving machine: https://goo.gl/CVZs2i Special offers on other CNC parts: https://goo.gl/rjNzpb
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Metal Casting at Home Part 16. Large Casting with Core.

09.12.2010
Casting the pattern made in part 15. The recessed rectangle at the top will be cut out later and is filled in to aid moulding.
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Metal Casting at Home Part 67 Double Sided One Part Pattern.

04.24.2017
If the pattern is the right shape a mould can be made without making a split pattern.
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Metal Casting at Home Part 17. Ten Castings with a Snap Flask

09.26.2010
Casting ten model cars using a snap flask to make the moulds.
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Metal Casting at Home Part 68 3D Printed Patterns Part 1

06.24.2017
An introductory video showing the printer I have. Next time I will be printing a pattern and using it for a greensand casting. Also I am looking forward to trying a lost PLA casting which will enable more intricate castings to be made. Links 3D printer special page: https://goo.gl/xEdxVB (15%off coupon: bgprinter) Creality 3D 3D printer: https://goo.gl/wXrkMi (20%off coupon: bg3dprinter) 3D Copper coloured Printer Filament: https://goo.gl/3RHbeQ IP Camera: https://goo.gl/JhMFS8 Figure Alex https://www.thingiverse.com/thing:7... Figure Sarah https://www.thingiverse.com/thing:2... Robot https://www.thingiverse.com/thing:1... Lucky Cat https://www.thingiverse.com/thing:1...
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Metal Casting at Home Part 18 Cantilevered Core

11.07.2010
This casting needed a core to produce the required shape. The core could only be supported at one end so a cantilevered one was used.
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Metal Casting at Home Part 69 3D Printed Patterns Part 2

07.01.2017
My first 3D printed pattern worked a treat. The finish on the print did not need any sanding, filler or paint, it was used as it came off the printer. Creality 3D® 3D printer: https://goo.gl/b5sIy8 (20%off coupon: bg3dprinter) 3D printer special page: https://goo.gl/eQwNi2 (15%off coupon: bgprinter) Bromsgrove greensand https://www.artisanfoundry.co.uk/pr... Planetary gears https://www.thingiverse.com/thing:6...
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Metal Casting at Home Part 19 Experiment with Core Making.

11.14.2010
This was an experiment to see if carbon dioxide produced with vinegar and bicarbonated soda could be used to harden a sodium silicate sand core. The result was a success and is a cheaper alternative to buying bottled CO2.
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Metal Casting at Home Part 70 Lost PLA Casting First Attempt

07.08.2017
After successfully making 3D printed patterns for sand casting I wanted to try lost PLA. I am very pleased with this printer the prints come out great 3D printer special page: https://goo.gl/xEdxVB (15%off coupon: bgprinter) Creality 3D? 3D printer: https://goo.gl/wXrkMi (20%off coupon: bg3dprinter) Investment powder https://www.artisanfoundry.co.uk/pr... Vase: https://www.thingiverse.com/thing:5... Robot: https://www.thingiverse.com/thing:1...
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Metal Casting at Home Part 20. Hit & Miss Engine Cored Cylinder .

12.31.2010
Making a greensand mould and casting an aluminium cylinder for a model hit and miss engine. ( Blooper included ! )
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Metal Casting at Home Part 71. Locating a Core.

07.29.2017
The most frequent question I get is how is a core held in the mould. The core creates a cavity in the casting so, for example, it can be made hollow. Here are 3 different methods of locating it to produce a cavity in the casting. Another method is shown here https://youtu.be/1HuxDVpy_iU which also shows how the cores were made.
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