Metal Casting at Home Part 2 Backyard Foundry

[blazterreck]

thanks for reading my question

[blazterreck]

ok thaks for telling me

[blazterreck]

"Myfordboy".would you know by any chance what aluminum grade soda cans are? 6010...7020

[myfordboy]

@blazterreck Sorry I don't know the grade only that they are rubbish grade and not worth melting. There is so little metal in them , they produce a lot of dross and the metal is not idea for casting.

[jeffroboy48]

@blazterreck basically anything below 1500 grade is considered "food grade" and has almost no structural properties worthy of a finnished product. Bicycles, cars, airframes typically use 6000- 7000 series aluminum, these have a higher percentage of other alloys such as nickel, zinc, magnesium and a few others. Food grade is basically pure aluminum.

[BernhardHofmann]

Must feel fantastic to make something like that. Excellent job. I'm clueless about metals. I don't understand how the tin you melt the metal in doesn't melt. Just a different metal? I could watch this all day - it's like Christmas when you remove the sand to reveal the mystery of what you made.

[myfordboy]

@BernhardHofmann The aluminium melts at a much lower temperature than the stainless steel crucible its in.

[blazterreck]

what do yo useto get the air bubbles out from the molten metal,could baking soda work?or....

[myfordboy]

@blazterreck I am using sodium carbonate: washing soda.

[pbylina]

How do you get the core out if its inside the cast?

Where do you get the special protective pants, gloves, mask and shoes?

[myfordboy]

@pbylina See myfordboy.blogspot.com for detailed information on cores. Tool suplier for mask gloves. Nothing special with the trousers other than knee pads, normal shoes.

[aflatminor]

@pbylina

The casting is open at both ends (and other bits too)

If the core was completely enveloped in molten metal, the gasses produced from the core would blow the molten metal up and out of the riser, this would be dangerous and also produce a scrap casting..

[shrimpinpat]

alll that time it would suck to screw up

[TheBJAdams]

Thanks, I meant crucible, flask=cope and drag. Excellent videos, I'll enjoy your blog.

[TheBJAdams]

is your flask a tin can?

[myfordboy]

@TheBJAdams The crucible is a stainless steel storage container. Flasks are made of wood.

[epineh]

Lots of great information in your video's, thanks for posting them.

[bojskiable]

i like the end credits

[jsrnf]

What do you mean by de-gassing ?

[myfordboy]

@jsrnf Aluminium absorbs hydrogen when melting and the degassing drives it away.

[jsrnf]

@myfordboy Thank You !

[110samec]

Did you make the furnace?

[myfordboy]

@110samec Yes. For details go to myfordboy.blogspot.com

[rutz08]

how do you get the core to be elevated so that the wall of the object being cast forms around it? also how do you get the core out??

[myfordboy]

@rutz08 Please visit myfordboy.blogspot.com

I have illustrated this in my FAQ. Core easily removed by digging out, can be softened by soaking in water.

[v8bmwboy]

Great job, and thanks for showing the failure. It wouldn't be casting without them...

[florettabombetta]

hey. I saw that you 've made the furnase yourself?

I'm specificaly interested in the 'clay' core of the furnase.

thanks in acvance.

[myfordboy]

@florettabombetta Please visit my blog myfordboy.blogspot.com where you you find full detalis of this.

[NewYorkRawVideos]

I noticed you weren't wearing a respirator, please do. Even though you are in a ventilated area, there's still the risk of breathing in fumes.

[boblob801]

Have you got plans for the furnace I could have?

[myfordboy]

@boblob801 Please go to myfordboy.blogspot.com where you will find the furnace plans and other casting tips.

[akaBeastMode101]

could i melt fake or real gold in thr

[myfordboy]

@akaBeastMode101 No

[akaBeastMode101]

@myfordboy and why is that?

[akaBeastMode101]

could i coat an object with this metal mixture? lets say a glock if i took the parts of the golck off and coated them

[myfordboy]

@akaBeastMode101 What is a glock?

[888bobdaduck]

@myfordboy a gun

[cgspeeddemon1]

@myfordboy its a popular handgun here in the states....and just fyi the anser would be no beacuse a glock is made of composit plastics

[azza44100]

@cgspeeddemon1 not all surely the more expensive ones are made of metal ? 

[cgspeeddemon1]

@azza44100 nope...glock is a brand name and their claim to fame is being the first manufacturer to make a reliable lightwieght handgun by using polymer frames.....oh and they ARE some of the more expensive ones

[Britishman00]

@myfordboy It is a pistol

[JohnnyI3oy]

I'm an Industrial Design student at the University of Dundee and this being the beginning of semester 2 have just begun a module called Engineering: Structure and Manufacturing. So far our lectures have just covered casting but I found this video very informative. It's good to have had a practical demonstration to go with all my notes! Thanks!

[helium73]

This is so cool

[TooLameToDie]

This reminds me of watching my grandfather work when I was little. Oh, and I love the bloopers at the end. Great job by the way!

[katarinajoan]

Good job ,sir

[trobro2001]

LOL well ty for the alt. ending its nice to see that it does not always go as planned.

some questions how much salt ang soda do you use per looks like you use a 2 liter bucket. and the core is made of same sand?

[myfordboy]

@trobro2001 I am using a teaspoon of salt and soda to 5Kg metal, not critical. I use builders sand for the core, I don't want to loose my precious moulding sand.

[trobro2001]

@myfordboy Ty I am thinking of trying this at my house another puzzling question I have is how does the metal form around the core evenly without the core being supported sorry may be a dumb question but i dont see how it works

[myfordboy]

@trobro2001 I have a detailed answer to your question at myfordboy.blogspot.com. See Casting hints and tips.

[lerpman1990]

was that slag you where scooping out at 1:45

?

[myfordboy]

@lerpman1990 Yes, dross (slag)

[fall22123]

It's nice to see someone casting with common sense safety equipment. I've watched so many people pouring wearing shorts and sandals with no safety glasses or gloves. I hope they don't have to learn the hard way.

[koviack]

@fall22123 i've also seen those videos, not gonna lie. lol'd hard

[tazadaar]

This video is great, I feel like today I learned something I could put to use some day

[MadDave]

Looks great!

[mrmatni1]

شكرا على الفيديو شرح واضح

[BlazinColdStoned]

@mrmatni1 Speak AMERICAN, boy!

Probly plottin to blow somwething up

[rsoneill21]

@BlazinColdStoned google translate

[ermarkov]

Goog video!

I was wondering how long it took you from start to end? (with the good casting)

[myfordboy]

@ermarkov With the core aready made and taking my time with the odd tea break, probably a couple of hours plus the clean up time afterwards.

[ermarkov]

@myfordboy Thanks.

[Lacrossanator1]

How do you get the core out? or is it left inside forever?

[myfordboy]

@Lacrossanator1 Core is made from sand so can be easily dug out from finished casting.

[daddyos50]

This was well done, great in it`s simplisity!

!rakishreed

[Luke00126]

How can I make my one furnace?

[myfordboy]

@Luke00126 see my video part 9 "The Furnace"

[shades2]

1:01 No more eyebrows! :P



[hhart6266]

This was a terrific series - I've only just become interested in casting and this has piqued my curiosity even more!

[chrisonline209]

I have a small tool that I invented and would like cast in steel. It is only about the size of a screwdriver. Can you do that for me. I would like about 50 of them to test market. Please let me know at chrisonline209@yahoo.com

[metalkidjohn]

What did you use as a crucible?

[myfordboy]

@metalkidjohn Stainless steel storage container.

[dsfrobots]

It was a little hard to see the core but, how is the core centered and floating between the two parts? If it touches the sides at all, that would leave a hole wherever it touched right?

[myfordboy]

@dsfrobots The core touches the sand mould in 3 places. The 3 places hold it in the correct location and are placed

where holes are required in the finished casing.

[handiest1]

Honey, where is my big silver salad spoon?

[myfordboy]

@handiest1 Sorry honey I've metled the end off it!

[kiresdl]

Does black sand have moisture? if so, how much?

[myfordboy]

@kiresdl See part 6 video

[Purecrystal994377]

Dear video maker my name is maria phillips and im interested in making my own jewellry using this method.As iam a newbie could you please give me al list of all the quipment and necessary materials i would need to create this wonder that you have made.I would be highly greatful if you would also please provide me with any thing else that you feel will be necessary for me.

[myfordboy]

@Purecrystal994377 For jewelrey you would be better off investigating the Lost Wax method of casting. This is more suitable for your needs.

[liljohnnotbigjohn]

would your mold burst without the vents?

[myfordboy]

@liljohnnotbigjohn If the core is not vented the metal expanding air can push the metal away from the core and leave a void. If there is no core this is not a problem. Although standard practice is to also vent from the pattern I don't usualy do this.

[liljohnnotbigjohn]

@myfordboy That is good to know :). Thank you for the quick reply and thank you on the EXCELLENT series on green sand casting. I have a book which details what you are doing, but seeing craftsman @ work makes it all makes sense.

[seewotididthar]

What is the function of the finished product?

[myfordboy]

@seewotididthar Finished product can be seen in my video "Model Monitor Hit and Miss Engine"

[rollyrunner]

how do you get the core out?

[myfordboy]

@rollyrunner The core is made of sand ( In this case mixed with various ingredients and baked in a oven) so can be dug out with a screwdriver. Soaking in water will soften it if necessary. You can see a core being removed in some of my later videos.

[bedofrazorsqwerty]

What are you spooning off around 2 mins there? I can't see IN so I have to ask. :) thanks

[myfordboy]

@bedofrazorsqwerty This dross. The impurities that float to the surface, like paint and oil on the metal. You can see it more clearly on some of the later videos.

[rollyrunner]

@myfordboy this might be a dumb question, but how do you get the core out?

[Intro11159]

Three questions. How would I go about making a similar home-made furnace (parts, price, tips, etc.)? How did you get the mold that you used? And finally what can be done about the color of the metal? Could you add something to end up with a gold color? Ok that's four questions. Great video btw

[myfordboy]

@Intro11159 I have a video showing the furnace contruction, I think you mean where did I get the pattern.... I made it. Its made of wood. You could use brass if you wanted a gold colour, you cannot change the colour of aluminium durring melting. If you watch the rest of my videos It will answer your questions.

[py1hy]

Thank you for this fantastic video!

[Anything2bCool]

That was amazing. Everything was really clearly shown. Thanks for the education!

[saviorslegacy]

@wyskasses Yes but can you cast metal hard enough to with stand the pressure of a bullet after it has been drilled?

I just want to know if you can cast metal strong enough to withstand an explosion from a bullet.

[ArmedBrit]

@saviorslegacy

as in a chamber of a weapon?

well in theory yeah... I mean they used to cast cannon and gun barrels like this until the 1860s and even later.

[saviorslegacy]

Could you cast something that stands up to the pressures of bullets?

Like a revolver cylinder or a barrel.

[myfordboy]

@saviorslegacy I only have experience with aluminium casting. I don't think this would be suitable unless the walls were very thick.

[doubleboost]

your vids are great

but you need some propper PPE i have been hurt with molten bronze

It is ok wearing gloves and a visor

Molten metal on a bare arm goes to the bone in seconds

Best thing is it dont hurt cos all the nerves are nackerd

Then its to late

Take care

[rhyboy1]

how do you get the piece from the middle out :S

[myfordboy]

@rhyboy1 Its only sand and can be easily dug out. Soaking in water softens it.

[rhyboy1]

@myfordboy ooh ok.

I'm thinking of doing somehting liek this for a small part for my car.

I have a 300zx and parts are near impossible to get.

[210482fmj]

is the metal produced from this technique good enough to make an engine block.

[myfordboy]

@210482fmj This IS an engine block

[gohuskies583]

Thanks for bearing your soul and showing us the outake. Im sure that was a bummer to find that out after all that hard work! But even Thomas Edison had failures! We've all done that. Really nice work, hats off to you!

[gohuskies583]

Really interesting! Do you have to remove the casting from the sand while it is still hot? If so, why? I am new to this so I realize I am asking a really elementary question. Thanks

[myfordboy]

@gohuskies583 It is not necessary to remove it hot. If you leave it in the sand though it would take ages to cool and I can't wait to see the results !

[gohuskies583]

@myfordboy OK thanks. I can appreciate that. Whenever I make something I always get impatient at the end cause I can't wait to see how it turns out. Thanks for your reply. Nice job on the videos. Looking forward to watching more of them.

[ferrisbueller9000]

DON'T HOLD THE LIGHTER UPSIDE DOWN, YOU LIGHT IT UP ONLY WITH SPARKLES.

[bearhedded]

I don't know how much of a difference it makes, but, not all washing soda is pure sodium carbonate/soda ash. Sometimes it is actually sodium decahydrate, and can contain salt, and other additives.

[myfordboy]

@bearhedded I don't think the salt would make any difference as I am already using this as a flux. All I can verify is the stuff from my supermarket works fine.

[bearhedded]

@myfordboy That's good! I may try to set something like this up, in my back yard...

[srikanth94]

why did u keep extended runner and risers.... anything specific?

[myfordboy]

@srikanth94 These give a "head" of metal to feed the mould as the metal contracts when it cools. Also makes pouring easier by making a funnel shape in the feeder.

[Truthhurts3pm]

You used another metal for the actual core, is there a way to cast, and then pour the melted metal into the cast and have a final result of a hollow product? Ex: how would i make a baseball without a core or without being solid all the way through? Is that possible?

[myfordboy]

@Truthhurts3pm The core is made of sand not metal. You need to be able to support the core within the mould so to do your baseball would need 2 core prints which would leave 2 small holes in the finished casting which would need pluging.

[jzj555]

this may sound like a dumb question, but my vocab on metal casting isnt all that good. whats slag?

[myfordboy]

@jzj555 I dont recall using that word.You probably mean dross. Its the impurities on the metal like dirt and paint that float on top and can be scouped off.

[cjoIIProductionz]

@myfordboy actually you said slag around 2:40

[myfordboy]

A plaster mould has to be very dry . Any moisture would cause an explosion with the hot metal turning it into steam, The heat would probably crack it too, not reccomended.

[superant10000]

Could you use a plaster mould to do this too? Or would it melt or stick or something?

Great cast by the way, looked amazing!

[myfordboy]

Core is made from sand, see my core making videos. Core cannot float its located in the impression left in the sand by the mould.

[fundreamer1]

What was the core made of? Did it "float" when you poured the metal to keep from laying on the bottom and coming through mold and ruining the project?

[hud42cdo]

really enjoyed the mold making and casting vids-so nice not to have to endure some droning septic....thanks for the vid-my metal casting is yet to start but i have been melting for a year or so,nice pile of ingots ready-where can i find the sand in the south,it all \seems to be north !!

[Supermassively]

LOL! Did you have any eyebrows left after it finally ignited?

[sukaii]

@myfordboy What kind of sand (dirt?) are you using  for the mold? And don't you need to preheat the mold before the casting?

Great vid!

[myfordboy]

@sukaii I am using a commercial greensand. No need to preheat.

[doubleboost]

@myfordboy

great video but is your skin made of asbestos

cos skin grafts really hurt

[aRothmansMK2Escort]

These vidss you made are brill!since june i made a furnace the way you show,i use a stainless steel pot (storage jar) and the sand i use is mansbond fine casting sand from John Winter & co ltd, £25 per 25kg bag,seems super stuff,started casting classic ford escort bits,unavailable mk1 indicator units,rs2000 engine mounts rs cam covers etc,thanks 2 you and your vid clips,im now making some VERY good money from it,anyone thinking of doing this,watch all the vids,and HAVE A GO! THANKYOU myfordboy!

[RrahimStruja]

Nice work, very educational vid, you probably know but to get a right amount of melted metal you could sink the original part you wanna reproduce in some glass container and take measures before and after you sink the object in the water, the difference would be the right amount of metal needed plus some 10-15 % more for the feeder.

[dantech1]

Thanks for you great videos !! Like everyone else on here, I have a couple of questions.

What grade of aluminum do you use ?? One would think that the castings would be so soft by using 1000 series, that they would be impossible to machine.

Have you tried casting with 6061? If so, what were your results?

Thanks again, Dan in Canada

[myfordboy]

@dantech1 Well, I have no idea what grade of aluminium I am using! Its all scrap from different sources. I do though only use metal that has been cast before, no extrusions or sheet.

[mollysangelique]

@dantech1 he,can,do,this,great,technical­l,jobs,angel

[Supermassively]

@mollysangelique ... what?

[HeadShot360IN]

too bad so much wasted metal... did some pewter casting in my metal art class.... yellow crap layer had to scrap off

[mygomez100]

Terrific sequence of videos. I'm still strruggling in my home foundry to find the right type of sand to use for a good clean finish. I mostly cast AL and Zameak Pot Metal. What type of sand do you use? Is it Oil Bond type? Also could you expound a bit more on your use of salt and wash soda for degasser and flux? Thanks for your help!

[myfordboy]

@mygomez100 Sand is not oil bonded but a foundry greensand. I think its a natural sand and I have been advised by a foundry supplier it contains coaldust.I have switched to Losalt in place of table salt which seems to get a better casting. washing soda is sodium carbonate. I think this is available in the US as pool shock.

[metalhead2508]

@myfordboy Pool shock is Calcium Hypochlorite. Sodium Carbonate is sold as Ph Up. It increases the PH of the water. Just wanted to clarify this so someone doesn't by the wrong stuff. Love the video.

[james12436]

how much would that cost

[jasmatk]

great idea with the torch as burner did you modify it at all?

[myfordboy]

@jasmatk The tube and jet are my own design I am just using the torch as a convenient

control.

[ish2388]

The sand which you use is gonna stick with molten metal or not??

Is the meatl alloy scarp is pure or powder coated or processed???

[myfordboy]

@ish2388 Scrap is clean but may have paint on it.

[ish2388]

Is the meatl alloy scarp is pure or powder coated or processed???

[FollowSmoke]

Why did I goof off in shop class? This looks unbelievably fun.

[lindamermaid]

Read all the posts, didn't see this question: How many times can you reuse the sand (if at all)?

[myfordboy]

@lindamermaid Sand can be used indefinetly

[FJoeForty]

Sodium Bicarbonate (Baking soda) can be made into Sodium Carbonate by putting it in the oven. At 400 F, it is immediately reduced. It will then float on top of water.

[cavman666]

got a few questions

what is the inner mould made out of, sorry it thats not its name which im guessin its not but i mean the peace you placed in the middle to make it hollow?

is it wood that you burn off? if not how do you get it out etc?

[cavman666]

@cavman666 ok you can ignore that, i found the 3rd vid, should put a link in the 2nd vid, or maybe i missed that bit lol

[myfordboy]

@cavman666 "Inner mould" is called a core. Its made of sand held together with a binder. It is easily broken ouy after the cast. If you watch the rest of my videos , all will be revealed!

[sarsgarrs]

very nice, I am new at casting and melting so this was very informative

[isaacownsyou]

dude where can i get that kind of sand from i've looked at lots of videos and no one wants to tell me anithing

[myfordboy]

@isaacownsyou I live in the UK so cannot help with a supplier in your area. A lot of US metalcasters make their own moulding sand by adding up to 10% bentonite clay to play sand.

[SuperAlmac]

@myfordboy Where can you get that sand in the UK?

[myfordboy]

@SuperAlmac I don't know where to get more of the sand I have but have been in touch with John Winter &Co who reccomend their DM sand. email carol white and say I sent you.

[brandonhud60]

@myfordboy Just for saying you live in the UK makes you 1000x better than all the video's i have watched, im 14 but i would like to take up metal casting as a hobby, but i dont know where, and when to start, would you be able to help with that? im in the UK aswell

[amardeep2230]

yeeeeeeeeehhhhhhhhh really nice......

Plz upload some new or great ideas in casting

[paperjack93]

Is aluminium sheet good for melting ?

[myfordboy]

@paperjack93 You are better off using a material that has ben cast before so you know its propeties are good for casting. Sheet materal has a lot of surface area and will make a lot of dross.

[EZOVALS]

Hello, nice casting I'll one day start casting too for now I'm just looking and writing information cause is difficult to find furnance and casting materials were I'm from, I was wondering how much salt and sodium carbonated u used? I'm planing to go on a oil furnance.

[myfordboy]

@EZOVALS I use about a teaspoon for 5kg metal

[dom99661]

what kind of cheap iron can be found to make a project similar to this

[myfordboy]

@dom99661 Please clarify your question

[dom99661]

@myfordboy im trying to do a project like this. but i want to melt some iron insted, because i want to build some thing kind of stuurdy for my mothers birthday. and i want to know where i could get my hands on some cheap iron. i was asking where i could find some cheap iron scraps or other things like that

[myfordboy]

@dom99661 You are in Canada and I'm in the UK so I'm not sure of the situation there. I would try a local scrap dealer. you are going to need a lot of heat to melt iron.

[kgeorgejunior]

what is that you remove at 2:29 and why did you do that? sorry about my english i am greek.very nice video btw.

[myfordboy]

@kgeorgejunior  This is the DROSS. Its impurities in the metal like paint and oil that was on the scrap.

[kaningraff]

@myfordboy how can i identify dross from the good melted metal?



[darthjeff3]

what exactly does the salt do?