Sand casting

[forgeblast]

I dont see a sprue though that you will be casting into. Sprues, Gates and Risers
The sprue will direct the metal where you want.
melting metal in a home foundry, backyard metalcasting, metal casting is also a good site.

 

[SPIKER]

I dont see a sprue though that you will be casting into. ...
The sprue will direct the metal where you want.
...

Agreed on the Sprue and for record that part almost looks like it would be better made using formed sheet metal/Plate. the way the part is setting in the casks I'm not sure where the flow path is going to go...

Anyhow might want to think about forming some steel which would hold up rather well vs cast parts.

I dont remember you saying what you were casting the part in? Aluminum, Bronze or zinc/lead ??


Mark

Curious what your intentions are for it?

 

[GMtb42]

I dont see a sprue though that you will be casting into. Sprues, Gates and Risers
The sprue will direct the metal where you want.
melting metal in a home foundry, backyard metalcasting, metal casting is also a good site.

Thanks, have done lots of reading and watching videos on casting.
I plan on using a tube to form the spruce and riser, I don't know if I will need any gates.

Agreed on the Sprue and for record that part almost looks like it would be better made using formed sheet metal/Plate. the way the part is setting in the casks I'm not sure where the flow path is going to go...

Anyhow might want to think about forming some steel which would hold up rather well vs cast parts.

I dont remember you saying what you were casting the part in? Aluminum, Bronze or zinc/lead ??


Mark

Curious what your intentions are for it?

I am using aluminum, would love to be able to heat and bend plate, but the contour is complex, angles with both curve and tilt to the part.
I made a mock up from steel rods is how I got the part formed in the first place. I am using a prototype right now for testing purposes,

It is a mud flap and want to move the license plate onto it at some point. The part is made so that when the chain is adjusted it follows the axle and maintains the same distance all the time.

No it is not a crouch rocket, I have turned into a sport touring rig, just like the style and riding position (full upright) and cc of engine (600).

You can just see my wife's ride's front wheel in the picture (Vulcan 900).

The part is a spinoff from Ducati and BMW motorcycles, both have models that have something similar.

 

[SPIKER]

GMTB: I see what you are making now, I would suggest making it out of sheet metal as cast aluminum will be somewhat brittle and vibration would more than likely cause some cracking/breakage riding on the bike axle like that. There are some easy ways to get that compound shape in sheet metal. I would head to TSC and buy a single Trailer Fender or look in some of the bike books for one you can cut up. Watch an episode or three of American Chopper this is what they do buy inexpensive full fender then cut it to the shape they want or hammer it into shape some. not hard to do either.

Mark

 

[GMtb42]

Mark,
I think you missed the part completely. I want to cast the arm not the flap. The whole assembly is a mud flap or tire hugger as they call it, mud flap is my moniker for it (based on Ducati's and BMW's part description too). In the picture of the part in wood (brown) you can see the second prototype laying on the floor it is made of 3/8" round bar (current one being used as in the picture with the yellow flap) I found with it that a gusset was needed to aid in strength, the original part concept 1 was made from 1/4" round bar so as to be easy to work with, the one in the picture with the red paper flap concept taped to it.
Wow hard to explain over the net.

The part in the previous post (post #18), first pictures, the red one, is the part that I want to cast.
When I looked at the Ducati, BMW ones they were cast aluminum parts, which I was surprised to see, they were 1" thick and looked like sand cast.
Again the arm is what I want to cast not the yellow piece. I have some 1/2" aluminum and just can't see beating and bending it into the arm part, the arm part needs to be at least 3/4" which is the casting parts dimension.

 

[SPIKER]

Ok a bit better understood. So the 1/4" rod did not workout then? 1/2" thick cast is a bit more stable in the photo looked to be rather thin material. Might try to cast it more of a I-Beam shape but would take a lot more effort in the mold. When you do go to mold it do try and get some temp into the sand prior to pouring, put some heat lamps onto the casks to get some heat into it. It will help flow and the added heat will let it cool slower giving a bit more strength.

I would also say to get full leather or nomex welding apron, full face shield and welding type cover. Dress from bottom up so overlapping layers will run any splash or spray off. There should also be leather boots with covers over the laces. (Having a large bead of molten metal land on laces and run around shoe strings into the foot is not fun I've seen it 1st hand.) One of my co-workers had weld blowout land on the cuff of his jeans which were bunched up a bit on top edge of his boot. It pooled on the jeans burnt thru & ran down in his boot onto his ankle... It was not pretty and did major damage to him...

Mark

 

[GMtb42]

Ok a bit better understood. So the 1/4" rod did not workout then? 1/2" thick cast is a bit more stable in the photo looked to be rather thin material. Might try to cast it more of a I-Beam shape but would take a lot more effort in the mold. When you do go to mold it do try and get some temp into the sand prior to pouring, put some heat lamps onto the casks to get some heat into it. It will help flow and the added heat will let it cool slower giving a bit more strength.

I would also say to get full leather or nomex welding apron, full face shield and welding type cover. Dress from bottom up so overlapping layers will run any splash or spray off. There should also be leather boots with covers over the laces. (Having a large bead of molten metal land on laces and run around shoe strings into the foot is not fun I've seen it 1st hand.) One of my co-workers had weld blowout land on the cuff of his jeans which were bunched up a bit on top edge of his boot. It pooled on the jeans burnt thru & ran down in his boot onto his ankle... It was not pretty and did major damage to him...

Mark

Thanks Mark,
I did think about a ribbing long ways down the back side for strength as you stated, might be something I will look into trying to work into the pattern piece, need to check clearances to make sure I can do it.
I do have full faced shield, gloves, but the apron I have is a denim one, must look for a leather one then, boots I will need to look for too.
Thanks Mark for the tips on the sand heating, I had thought about that but not the way you described, I do have some heat lamps and will use them.

 

[podieroe]

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