TOOLS, Casting the H.A.M.B. Lucky Star! - - - HOT! - - -

[whizzerick]

WWII is over... Defense Funds are cut off...
Industry is looking for NEW avenues... The thirst for speed is ever present...
New ideas meet new technologies... Edelbrock has an idea for a new intake manifold...
Foundries are hungry for new business... Timing is perfect...

Follow along as we re-visit Hot Rodders infatuation with that most modern of metal: aluminum.

Welcome to this TECH:

http://www.whizzerick.com/ssss.JPG

[whizzerick]

Design stage.
http://www.whizzerick.com/a-%20designing_topper.JPG

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Pattern fabrication. Using Forstner bits and MDF.
http://www.whizzerick.com/b-making_star.JPG

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Parts are assembled. Letters positioned.
http://www.whizzerick.com/c-Fabricating.JPG

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Finished pattern.
http://www.whizzerick.com/d-Assembly.JPG

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Priming. Sanding with 600.
http://www.whizzerick.com/e-Priming_pattern.JPG

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Oven curing lacquer.
Wife screaming in background.
Divorce threats...
http://www.whizzerick.com/f-Oven_drying.JPG

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In the shop, foundry setup.
http://www.whizzerick.com/g-Foundry_setup.JPG

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Pattern in the drag section. Applying parting dust.
http://www.whizzerick.com/l-pattern_in_drag.JPG

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Drag section rammed and flipped over.
http://www.whizzerick.com/m-Pattern_rammed.JPG

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Pattern exposed. Crisp molding. Nice definition.
http://www.whizzerick.com/n-Pattern_exposed.JPG

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Cutting the sprue (entry) in the cope section.
http://www.whizzerick.com/o-Making_sprue.JPG

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Gating the Lucky Star.
http://www.whizzerick.com/p-Gating_pattern.JPG

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Firing the 50$ furnace.
Old blow dryer was obsolete: I am now bald...
http://www.whizzerick.com/q-Firing_furnace.JPG

[whizzerick]

1850 degrees of swirling heat!
http://www.whizzerick.com/s-Swirling_heat.JPG

[whizzerick]

Aluminum Muffins (ingots).
http://www.whizzerick.com/t-Aluminum_muffins.JPG

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Rare 'Wheelium' alloy... http://www.jalopyjournal.com/ubbthreads/images/graemlins/wink.gif
http://www.whizzerick.com/u-Wheelium_source.JPG

[whizzerick]

The pour. Exciting!
http://www.whizzerick.com/v-Pouring_alloy.JPG

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Mold 'Shake out'.
http://www.whizzerick.com/w-Mold_Shake_off.JPG

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Success!
http://www.whizzerick.com/x-Result.JPG

[whizzerick]

Polishing. Dice cut in half and positioned.
http://www.whizzerick.com/y-Cleanup_assembly.JPG

[whizzerick]

12 volt diode installed.
http://www.whizzerick.com/z-Light&dice.JPG

[whizzerick]

Wired.
http://www.whizzerick.com/z2-Back_topper.JPG

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Masking the Star.
http://www.whizzerick.com/z3-masking%20_paint.JPG

[whizzerick]

Applying transluscent Krylon Stained glass paint.
Very muck like 'candy apple red'.
http://www.whizzerick.com/z4-Krylon_Stained%20Glass.JPG

[whizzerick]

Putting the HAMB Lucky Star up for raffle:
raffle (http://www.jalopyjournal.com/ubbthreads/showflat.php?Cat=&Board=UBB1&Number=329796&page=0& view=collapsed&sb=5&o=14&fpart=1) http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

There you go, folks.
I hope you enjoyed this as much as I did making it.
whizzerick

[burndup]

Rightous... thanks!

and thanks for the tip on the Kandy paint, been wondering where to find it nowadays!

-J

[Hot Rod To Hell]

That's awesome! I have a few question though:

1: did you just use regular sand?
2: What was the "release powder"?
3: Can you go into a little detail of your oven construction?
4: do you need to shake the mold or anything to prevent air bubbles?

I think that's it! Thanks again, this post rocks!

[Broman]

Ok this is pretty damn cool. I would want to learn more about this but I am certain I'd burn down my garage. What if a person just wanted to send you a pattern and pay you for your troubles...what would be the limitations on the patterns, like how much detail is too much and how thin is too thin, blah blah blah.....

[antichrysler]

This post is great. I have all the same questions. That's awesome.

[Ryan]

whizzerick, you truly amaze me... So cool, so smart...

[Harrison]

Awesome!!

[whizzerick]

HRTH, this is a lenghty answer:
Sand:
the sand casting process has been the same for hundreds of years. Traditionally, the sand was mixed with water and Bentonite clay (a natural occurence in Wyoming and various regions in the US). It is used in petroleum drilling for it's absorbency: a cup of Bentonite clay can gel 5 gallons of water... It is the main ingredient in KITTY LITTER.

Bentonite clay can be de-naturized into Bentone38, an OIL receptive product used in house paint. I followed a recipe called K-Bond (for Kent University, where students developped it). Sand (olivine-140mesh) + Bentone (bought at a local paint manufacturer) + Indopol (synthetic 2 stroke Oil ) + Isopropyl (rubbing) alcohol (catalyst).
Total cost: 50$ for 100 pounds!
The alcohol kicks the Bentone in the balls, causing it to open up and soak up the oil, that sticky mess then gobbles up the sand... Simple but effective!
Powder:
It's talcum powder. For baby's butt...
Oven:
Basically sheetmetal rolled into a cylinder with a sheetmetal base. I placed a 9 inch cylinder (an old chimney section) into the big one and poured a mix of refractory cement. That's the stuff masons use to lay bricks in the fireplace. It can whitstand up to 2800 degrees!

The beauty of oil based sand is that it DOES NOT produce steam the way water based casting does, so you rarely see bubbles...

I hope this helps?
wz.

[whizzerick]

Broman, this is just a hobby for me...
Most of my work is virtual now and I needed something 'hands-on' for creative output...
There are outfits out there (like O'brien Truckers) who have been keeping the torch of plaque and accessory casting lit for years. Even when the trend turned to billet.
Hat's off to them, send more business their way!

[wingnutz]

I felt as though I was back in shop class...! http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

You win this tech week...! http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif Pick up your trophy now so that we can start another tech week right away! http://www.jalopyjournal.com/ubbthreads/images/graemlins/wink.gif

Mark

[porknbeaner]

Well now that I know its not really an archeological find I'll win for sure. http://www.jalopyjournal.com/ubbthreads/images/graemlins/wink.gif http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

Good tech, I'll have to keep it for when I get serious about casting some pieces.

[hotrodladycrusr]

YOU ROCK! Very cool tech post! and your narration kept me smiling. You've got a great sense of humor.

The winner of the "Lucky Star" will be one lucky HAMBer indeed.

[Hip]

What an excellent tech!!! "whizzerick", if your not an instructor as a side line you should be, because when i can understand the instructions the first time around, and not have to go back and re-read to understand axactly what is trying to be explained, thats saying alot. Great tech http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[Zeke]

[ QUOTE ]
Finished pattern.
http://www.whizzerick.com/d-Assembly.JPG

[/ QUOTE ]

Note that all the sides of the pattern are angled. This is important guys!! To get a clean release of the pattern from the mold you must have some angle on the pattern. The angle doesn't have to be great just about 5 degrees or so.

[Hip]

[ QUOTE ]
Oven curing lacquer.
Wife screaming in background.
Divorce threats...

LOL! I know exactly what your talking about here Whiz. I used to bake on crinkle paint on bike heads in the house oven with the same threats screamed at me! http://www.jalopyjournal.com/ubbthreads/images/graemlins/smirk.gif

[Unkl Ian]

[ QUOTE ]
Oven curing lacquer.
Wife screaming in background.
Divorce threats...

LOL! I know exactly what your talking about here Whiz. I used to bake on crinkle paint on bike heads in the house oven with the same threats screamed at me!

[/ QUOTE ]

Timing IS everything.Just wait until she goes to the Hairdresser. http://www.jalopyjournal.com/ubbthreads/images/graemlins/cool.gif

[hotrodladycrusr]

[ QUOTE ]

Timing IS everything.Just wait until she goes to the Hairdresser. http://www.jalopyjournal.com/ubbthreads/images/graemlins/cool.gif

[/ QUOTE ]

coming from a single guy........ http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif Trust me, she would know. That stuff smells, and is toxic I'm sure.

You guys need to go out on the trash day of the month when the city picks up old appliances (last Wed of the month here) and find an old oven for the garage. Might save the marriage, and your health as well. http://www.jalopyjournal.com/ubbthreads/images/graemlins/wink.gif

[whizzerick]

Zeke. Thanks for bringing that up.
Kitchen AND foundry savy, are you?

[4t64rd]

Where did you get the plans to make the furnace?

If anybody in my area (West central coast of FL) needs an oven, I have a double oven (twice the capacity, twice the fun) free, come and get it! If you are close enough, I'll bring it to you.

[Drewfus]

* Creative mind
* Professional approach
* Forward thinking (well documented/explained)
* Generous & Supportive
* Humble in response

Hands up, you are a winner. Thanks for your efforts, I'm sitting here dumbfounded how awesome that little star is.

The finishing touch would be seeing it fitted on an Aussie car.....like mine http://www.jalopyjournal.com/ubbthreads/images/graemlins/wink.gif http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

Thanks again for the effort,

Drewfus

[general gow]

I know it's only Monday, but this wins for sure. Just too cool. http://www.jalopyjournal.com/ubbthreads/images/graemlins/cool.gif

[hotrodladycrusr]

You can only win it Drewfus if you send your envelope in. http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif Send it now and avoid the rush http://www.jalopyjournal.com/ubbthreads/images/graemlins/wink.gif

[Zeke]

Foundry, plastics molding and vacuum forming, gunsmithing, kitchen,and a few other things http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

Good tech man. How'd you manager such a nice cast without a vent? the few castings I've done I've always used a vent.

[Bugman]

What kind of fuel are you using for your furnace? Just propane, or something else?

-Jeff

[whizzerick]

[ QUOTE ]
Where did you get the plans to make the furnace?

[/ QUOTE ]

4T64RD, it all started 5 years ago when I came across an old, worn out copy of 'How to cast Small Metal Parts' by Bill Cannon. He builds a 20$ furnace (in the 60's) using an old metal 5 gallon paint container, an old hair dryer and propane. I derived my furnace from his basic explanation and some info I found on the web.

[whizzerick]

Drewfus, thanks for the kind words.

[whizzerick]

[ QUOTE ]
I know it's only Monday, but this wins for sure. Just too cool. http://www.jalopyjournal.com/ubbthreads/images/graemlins/cool.gif

[/ QUOTE ]
ModelAcoupe, I think TECH week should start with a KA-BANG!
But if one wants to WIN, one should post later in the week...
The 'excitement' wears off, Paris Hilton wears a Von Dutch T-Shirt and then you're on page 2! http://www.jalopyjournal.com/ubbthreads/images/graemlins/smirk.gif

[nailhead_sled]

Seeing as you are from la belle province shouldn’t your posts be in both official languages? http://www.jalopyjournal.com/ubbthreads/images/graemlins/wink.gif Next time I’m in Montreal I’ll be skipping the Super Sexe and heading directly to your place to check out your cool set-up.
Simply put, that is the coolest topper ever, period

[whizzerick]

[ QUOTE ]
What kind of fuel are you using for your furnace?

[/ QUOTE ]
Propane from my barbecue tank...
I cut the supply line and inserted a 1/4 inch brake line.
The line is MIG welded to a 1 inch steel pipe.
It takes very little gas and lots of air.
It can melt 5 pounds of aluminum 'ingot' in 15 minutes.

[A32Flathead]

What a great post, well done...

The winner in my humble opinion.

http://www.jalopyjournal.com/ubbthreads/images/graemlins/cool.gif

Dave

Saw this one on a car locally, thought it was cool....

[whizzerick]

Wow Nailhead, you actually spelled Super sexe in french! C'est très bien, mon cher ami!

[clint b]

The Winner....By a landslide, and it isn't even Tuesday yet.

[59BuickWagon]

Real nice casting Rick and thanks for the plug.

Didn't you show us a Whizzer part you cast once? I remember it because it was finned http://www.jalopyjournal.com/ubbthreads/images/graemlins/smirk.gif

Dennis

[whizzerick]

[ QUOTE ]
Didn't you show us a Whizzer part you cast once?

[/ QUOTE ]
Yes! My very first part: the Whizzer finned point cover.
Dennis, if I ever get a chance to meet you, I'd love to hear more about your shop. I'd be great to see a feature in a mag sometimes?
HEY! Any editors out there interested in a feature on 'trad' techniques? Enough with the IFS's!

[Buick59]

Now that is KEWL!!!!!!!!!!

Mike

[hotrodladycrusr]

[ QUOTE ]

HEY! Any editors out there interested in a feature on 'trad' techniques? Enough with the IFS's!

[/ QUOTE ]

Great idea, I'm going to forwward this link to the powers that be at Rodder's Digest. They understand homebuilt.

[old beet]

Really NICE job on the tech, Thank You.....OLDBEET

[59BuickWagon]

HAHAHA Denise. I know the Big Cheese does 'cause I've spent many a night in a parking lot with him, but I don't think the "power" dude does. He's into GPS burgular alarms and satellite radios.

[briggs&strattonChev]

hey thats awesome! Ive wondered about how things are cast.

Does anyone know how durable and smooth that stained glass paint is?

[Toqwik]

Man that rocks !!! And I am happy when I weld two pieces of metal together and they don't fall apart. Wish I had a talent.....To

[4t64rd]

Last year after Christmas I was in WalMart hardware section (yea, so shoot me) and they had Krylon Christmas paints on clearance. They came with 16oz. cans of silver and candy red or green, marked down to $5.00 a set. I picked up a couple red sets and it's the same quality as Krylon clear. I painted the top of a lawn chair and it still looks pretty good sitting outside since Jan.

[BARNETT]

Cool.

[Suede57]

Ive always wanted to know how to do that cool

[whizzerick]

Bttt, if you dont mind.
It's only tuesday... http://www.jalopyjournal.com/ubbthreads/images/graemlins/smirk.gif

[zman]

No problem take it back up, that's where it belongs.

[Jeff Norwell]

All bow to the molton HAMB foundry man!!!! http://www.jalopyjournal.com/ubbthreads/images/graemlins/shocked.gif http://www.jalopyjournal.com/ubbthreads/images/graemlins/shocked.gif http://www.jalopyjournal.com/ubbthreads/images/graemlins/cool.gif
Whizzee...yer incredible......When I get to Montreal....I'm buying the poutine and a coupla cases of Fifty!!!!! http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif
Awesome tech post!!!!!

[Jeff Norwell]

..are you the guy responsible for those French flatheads!! http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif http://www.jalopyjournal.com/ubbthreads/images/graemlins/cool.gif

[Roothawg]

Can you reuse the sand mixture after it has been fired?

[whizzerick]

[ QUOTE ]
When I get to Montreal....I'm buying the poutine and a coupla cases of Fifty!!!!! http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[/ QUOTE ]
Brush, not to disappoint your tastebuds but, I'd rather have sushi and hot Sake, if you dont mind...

[whizzerick]

[ QUOTE ]
Can you reuse the sand mixture after it has been fired?

[/ QUOTE ]
Root, yes you can. It even gets better because the heat activates the coating properties of the Bentone. There is a 'crust' of burnt sand that should be scraped off (it usually falls by itself) but even that CAN be re-vitalized with active ingredients.

[Roothawg]

The possibilites are endless.......I gotta try it.

[whizzerick]

I'm not gonna lie to ya: it takes commitment.
But it's a very rewarding craft, almost primal?
Imagine showing up in a modified with a Hopped-up inliner with this on the side:
http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[zman]

Make 'em and I'll buy 2....

[Dan]

Whizzerrick-
Awesome craftsmanship, what would you charge me to cast the parts of a Gingerly lathe, seriously let me know.

[Broman]

Man I ordered first!!!!, Make me one ,make me one,c'mon me first - Gimme Gimme.

BTTT

You're tied with the Hard-Top tech now.....but you score some major cool points with that last pic.....

[Bigdaddy]

wow, that is some good shit man. Id like to get one if you start amking them to.

-Bigdaddy

[autocol]

rick... wow.

awesome.



for those interested in home-foundry stuff, there is a LOT of information on the web if you look for it. i lost a lot of links in the great hard drive crash of 02 unfortunately, but here's a good starting point...

http://www.lindsaybks.com/dgjp/djgbk/char/

search for stuff by david gingery and you'll turn up LOTS of hobbyists who've tried this style of thing.

again, great post rick. buy a cigar and smoke it guy 'cause you rule.

[whizzerick]

Thanks Autocol, this is the little book that helped me (and a LOT of hobbyist) get started:
http://images.amazon.com/images/P/0830604146.01.MZZZZZZZ.jpg
I picked up from there with a LOT of good info on the web.

Funny how it all goes: there is a true 'grass roots' movement towards old crafts, revitalizing older techniques, re-discovering industrial history, all fueled by this new technology: the world wide web... How 'Post-Modern'! http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[Broman]

I have to ask, sorry to run off topic.

Autocol, how'd you get that avatar to run? I tried one a while back that was animated and it didn't animate while on screen. What's the trick?

Also, whizz, I was first so if you are making more I get to be first, cause I still think I'd burn down the shop.

[hotrodladycrusr]

[ QUOTE ]
how'd you get that avatar to run? I tried one a while back that was animated and it didn't animate while on screen. What's the trick?



[/ QUOTE ]

No real trick really, you just have to have it hosted on a site that allows .GIF files. Then copy and paste here under your advatar info. http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[CharlieLed]

[ QUOTE ]
Thanks Autocol, this is the little book that helped me (and a LOT of hobbyist) get started:
http://images.amazon.com/images/P/0830604146.01.MZZZZZZZ.jpg
I picked up from there with a LOT of good info on the web.

Funny how it all goes: there is a true 'grass roots' movement towards old crafts, revitalizing older techniques, re-discovering industrial history, all fueled by this new technology: the world wide web... How 'Post-Modern'! http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[/ QUOTE ]
Thanks for the great post and the recommendation for the book. I found it on Amazon.com and also bought three other related books on sand and investment casting. I have been working on building a portable kiln for my wife using Kao wool, now I have more motivation to get it done! http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[littledeucecoupe427]

That is some sweet stuff there, keep it comming!!!

[dadseh]

How to Cast Small Metal and Rubber Parts
Author: Cannon, William A.

available at all wall.mart stores


List Price: $14.95

Our Price: $9.42

You Save: $5.53 (37%)




Availability: 1 business day to process before shipping.

Shipping Cost: To see the shipping cost for this item, add it to your cart.

[whizzerick]

I posted this TECH on Monday...
Saw the shot bags up for prize on wednesday...
Brought it BTTT from page 5 on Sunday?
It's tech WEEK! Not TECH 72 hours! http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[TheDooWopKid13]

[ QUOTE ]
I'm not gonna lie to ya: it takes commitment.
But it's a very rewarding craft, almost primal?
Imagine showing up in a modified with a Hopped-up inliner with this on the side:
http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[/ QUOTE ]

that is so f**king bad ass. i want one of those

[Paul]

btt

[autocol]

i'm bumping this again... it's too damn cool.

someone put this in the T-O-M...

[burndup]

Hey, where do we 'mericans get that kandy "stained glass" paint?

I went to OSH and went as far as stepping foot into Lowes today and dint find it... anybody seen it around????

Thanks,
J