Showing posts with label casting. Show all posts
Showing posts with label casting. Show all posts

Saturday, March 24, 2018

Mystic River Foundry

I can't remember the site I found this nice file on. The author did not sign the file but he mentions students and a slide display, so it may have been a school shop site.

The author purchased a pattern set at a flea market and decided to have it cast at a close by foundry, "Mystic River Foundry" in Mystic, Connecticut. The foundry owner invited the author to come on the casting day and observe the step by step process, from pattern to finished castings. The 52 picture slides document the process very well.

The pattern set looks like a small gear box, smaller but similar to the gear box required for one of the hand operated grinders in the Advanced Projects post. I mention this to point out that it is not really as difficult as it looks.

Sharon Hertzler the owner, who doesn't mind getting her hands right in there, does a great job. A good example to all those critics on line, who like to deride the hobby casting process every chance they get (I think the term is "grow a set"). Having a big guy like the foundry man around to help with that big crucible sure helps a lot, ha ha.

To download this file click Mystic River Foundry. 2 MB - pdf

Very nice little foundry with some talented people operating it. There is a link to the foundry site in the file. Check out the fine work they do.

Navy Foundry Manual

So its been a long time since I spent any time going over my collected word files. For a slow connection its amazing how many files I put together my first few winters here. I spent this morning converting half a dozen to pdf's so I could upload them.

The first is considered by many as the bible of small shop casting and founding. "US Navy Foundry Manual" was first published in 1944, this is the newest copy published in 1958. I originally found it on an  armed forces historical site it was in html, I imported it to word where its been for over ten years. Wouldn't you know it shortly after Lindsay Publications did a reprint with a colorful cover as opposed to the drab business like Nav cover.

The manual is top shelf, covers everything needed to cast good castings. Pattern making, casting design, molding, melting and pouring, metallurgy, good and bad practice and most other information you might need to pour successful castings.

Because my word doc was 344 pages I was afraid my file might be to large to upload but it is a very clean file and the pdf came in at a nice 7.4 MB. If you cast or like to read about it, you will like this file.

To download "US Navy Foundry Manual" go to my Books - Free Downloads page. # 52 - 7.4 MB - pdf

The picture of the cover is from my Lindsay copy, just to add color to the post.

Friday, March 2, 2018

Production Molding Patterns

It's been a while since we posted anything on the casting process so here's an article some will find useful and most will find interesting.

So you have built a functional small foundry, developed a nice tool or product, built a prototype and worked out all the kinks. You have determined that there is enough demand to make it worth your while to produce and sell. You may decide that selling a casting set for the diy'er is more profitable or a partly machined set will be in greater demand. Either way you will need to set up accurate and interchangeable casting production. For small to medium sized castings aluminum match plates is a reasonable way to go. There are more accurate methods and I will post some of them in later posts from this book, but for most castings, match plate molds are quick and inexpensive to produce.

"The Giant Book Of Metalworking Projects" published by Tab Books Inc. in 1983, (yes you have seen this in at least one previous post) is cover to cover full of great projects and metalworking information. Picture quality is not that great, but that applies to most Tab books. Quality has improved since McGraw Hill bought them out years ago. There are other casting methods outlined, with plans, in this book, such as the shell molding process. The book covers a huge number of metalworking methods with lots of plans sprinkled throughout the book, to demonstrate these methods. I will be sharing many more articles from this volume in future posts.

So back to our small casting kit business. You can produce a lot of accurate interchangeable castings using durable match plates in a non-ferrous operation. For iron and a small cupola it would be folly to try without a couple of staff to help out.