Bugatti T57/59 Engine Project

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Got the mould box done. Just need to sort the partition mounting.

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Got the sump inner core pattern assembled and painted. Should be a lot easier to sand than the outer pattern!

This gives a visual on what its making. The main inner core. A couple of smaller cores attach to it.

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Chassis Update:

My Dads been working away on this when he has a spare minute.

Been making various press tools and working out a process.

Starting to look like a chassis rail! Not the easiest way of doing it but definitely the most authentic! 

Also if anyone needs a clock or a barometer restored hes your go to. As long as it doesnt take away chassis building time!

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Main inner core pattern is complete. Will most likely do a partition in the middle of this one too.

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The last inner core patterns prepped.

Now just have the runner pattern and box to figure out.

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Did an awesome trade today. I now have a T57 crankshaft.

Pretty lucky that it was less than 2hours away from me and the guy was awesome. Traded a bunch of my Lotus stuff + few $, he definitely did me a solid!

 

Crankshaft from Engine #210

Rods from Engine #293

 

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Finished the runner system pattern. So now all the sump patterns are complete, waxed and ready to go! . Only took 4 months.haha

 

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Pulled the bellhousing inner core. Came out ok.

I fill the pattern with raw sand first to get an idea of how much I need to mix. Messed up by 1/2 a kg so had to franticly mix more which meant I didnt pack it well enough. Still more than fine to use.

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Got the camgear covers sent over.

Looks like the real deal.

 

  

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Starting to fill the main pattern.

Got about a 1000lbs of sand on hand at the moment. Should be enough to do the sump 

Also trying out a proper foundry spray on pattern release. Hopefully it works! Because if my pattern doesnt come out that would be a terrible day/4months worth of work!

Have the pattern half full now. I had originally planned more sections but Im having a go at doing it in 4 pieces. That means mixing upto 50kg in one go. Thats hard work!

80kg so far. Another 90 to go!

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Got the rest filled up. We're at 170kg! . Thats a lot of mixing.

Now need to figure out how to turn it over without dropping it!

 

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Got it flipped over without too much drama.

Then removing the pattern was a lot of drama!

Took a whole day of slowly wiggling it out with pullers. Usually you pack the sand and 10minutes later pull it from the pattern when its still a little soft. With it sitting for days it was as dense as rock so I had a hell of a time.

Came out ok enough. A few cracks and damages to the sand and a few to the pattern!

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Filling the inner core next.

Its about 75kg so cant fill in one go. Going with a partition again but Im going to tie it together a bit better. I think a few threaded rods should work and Ive put some deeper keys in the partition wall/plate. It also needs some lift points so ill put some eye-nuts lifting off the threaded rod.

This is where the part goes. Suspended in the middle of the main mould.

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That worked quite well.

Used a different mould release, sand just fell out of the pattern.

Rods are holding it together well by the looks.

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Got the runner and other small moulds sprayed with the same stuff. Way easier/quicker than using wax release! . This will save me a ton of time going forward. 

The runner is 110kg so its going to be in 3 pieces.

Just finished printing some partitions. These are the jobs this printer is made for! Instead of spending hours making something from wood I can spend 30 mins on the computer and then its done by the morning!

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Partitions assemble like this. They look overly complicated but once the rods are fixed in place with sand its tricky to remove the walls so need them to split up.

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Runner mould done.

Was being a bit too fast and didnt mix the sand as well as I should have. Really soft section at one end. This wouldnt be good because it would erode like crazing and send sand through the fill.

Managed to cut it out and repair it. Hopefully it doesnt leak.

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Got the small cores made and bonded in.

Will try not to break them off when installing the main core.

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All the bits ready to go together.

 

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All assembled. Quite a mission. Not my best work but I'm learning a lot. Total is about 380kg.

Now I need to make a pallet and tie it all together well enough so that when it’s tipped over to horizontal it doesn’t shift around.