Popular Post Not-a-number Posted April 19, 2021 Author Popular Post Share Posted April 19, 2021 Got it down without dropping it or injuring myself! Been a productive weekend. Just need to add some walls and pack some extra sand around the areas im worried about. Then will be good to go to the foundry! 27 1 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted April 20, 2021 Author Popular Post Share Posted April 20, 2021 Finished and loaded up. Probably the most expensive and elaborate way to lower an El Camino! Looks like we'll see how good these bump stops are! 50 4 1 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted April 21, 2021 Author Popular Post Share Posted April 21, 2021 Well it didnt 100% work. But it could definitely be fixed with a welder! It didnt fill fast enough and there wasnt enough pressure. So they had to frantically fill from one of the riser holes to try save it. In doing that there is a big section of cold lap and a big hole! So the changes would be to have 2 filling sprues in the middle of the casting. Then increase the head pressure a little bit. The bowl I had in the sprue was way too big and reduced the head pressure. For the most part it looks pretty good. All the finer details are there. No cores collapsed or shifted, no shrinking of any areas so I dont need to worry about chill blocks. El Camino for scale. Going to have to figure out an easier way to do this in the shed. Was way too much work! 50 3 1 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 2, 2021 Author Popular Post Share Posted August 2, 2021 Time to have another go Got almost a ton of sand, new resin system and a new insulating spray for the moulds (meant to help big thin castings). Planning to use a concrete mixer to do larger batches. Doing some repairs to the damaged patterns. Drilled holes in the print and injected concrete epoxy. Also adding a few bond on thread plates to hopefully get a slide hammer on. 34 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 3, 2021 Author Popular Post Share Posted August 3, 2021 Doing 2 sprues/filters on this one which each feed one side of the casting. There will be more volume but also the mould is higher with no basin which will give more pressure. Completed the box. Quicker and cleaner than the last one. Next will be the runner system pattern/box. 23 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 3, 2021 Author Popular Post Share Posted August 3, 2021 Runner system pattern complete. Re sprayed everything with the better mould release. All patterns ready to go now. Next will be testing out the new sand resin system to figure out ratios and work times. Dont really want to go all in with a 200kg batch first go! 36 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 5, 2021 Author Popular Post Share Posted August 5, 2021 Did the bellhousing part using the mortar mixer. Gave me atleast a 45min work time on a hot day. Probably 3x as long as the last resin system. Picked up a 6cuft concrete mixer. El Camino for scale. Mixed 70kg for the runner system mould without much issue. Wasnt a perfect mix but I have time to leave it mixing for quite a bit longer. So will try that first. 26 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 5, 2021 Author Popular Post Share Posted August 5, 2021 Main inner core done. 75kg It removes from the patterns so much easier than last time. Now need to do the largest one at 230kg. No idea how thats going to go! Added a lift point as that helped last time. 40 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 6, 2021 Author Popular Post Share Posted August 6, 2021 Mixed 250kg in two batches. Super hard work and now I can hardly move! I think I need to do a single partition or take it to the foundry to fill. 20 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 7, 2021 Author Popular Post Share Posted August 7, 2021 Pattern came out a lot easier this time. Mould looks pretty good for the most part! A few little areas that didnt pack well and also damaged some of the sharp corners. Close enough to good enough 35 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 8, 2021 Author Popular Post Share Posted August 8, 2021 Sprayed everything with the insulative coating. Youre meant to set fire to it just after spraying, but the shed was pretty hazy and Im sure the spray is 90% alcohol. So didnt want to explode the house! Got all the riser holes and vents done. Dry fits together well. 20 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 9, 2021 Author Popular Post Share Posted August 9, 2021 All glued up. Ready to clamp it down to the pallet, then drop it to the ground. Went a lot smoother than last time but still a big big mission. Need a bigger area and a better way of mixing sand. I think its a little lighter than the last one. In preparation I added some 'helper' air bags to the El Camino a few weeks back. Should be good for 1000lbs..... 38 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 10, 2021 Author Popular Post Share Posted August 10, 2021 Loaded up. Suitably sketchy process, no injuries though. Air bags doing the job for now. 26 1 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 10, 2021 Author Popular Post Share Posted August 10, 2021 Ohh yeah it worked!!!! One minor defect where one of the thin standoffs didnt vent. But thats a simple weld job. Other than that it went awesome! She was a pretty big job! 71 6 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 16, 2021 Author Popular Post Share Posted August 16, 2021 Cleaned it up a bit. Took some rough measurements and it looks like it has shrunk the right amount. Machine allowance. About 4-5mm. 43 1 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 17, 2021 Author Popular Post Share Posted August 17, 2021 Round 3. Filled the patterns at the foundry. So much easier. 30 minutes instead of 3+ days! The strip time is about 10mins on this sand. It took me an hour to get them home and by that time it was pretty hard to remove the main pattern. Had to use the slide hammer setup. Little bit of damage to the pattern and sand but nothing too major. 29 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 19, 2021 Author Popular Post Share Posted August 19, 2021 Getting the hang of this. Ready to go to the foundry tomorrow. Did a few small mods to the runners and risers. See if it cleans up the defects. 24 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 19, 2021 Author Popular Post Share Posted August 19, 2021 Went well Slight defects on the top of some fins in one area. It must be low pressure there becuase you can see its starting to chill quick in that area on all 3 castings. Its not that smart having the thinnest sections at the top of the casting in hindsight. Another quick weldup and itll be good. 22 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 21, 2021 Author Popular Post Share Posted August 21, 2021 Cleaned it up. Stoked with how they turned out. 53 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted August 26, 2021 Author Popular Post Share Posted August 26, 2021 Quick video. Condensed a years worth of work into 4mins. 27 4 Quote Link to comment Share on other sites More sharing options...
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