Author Topic: Garys new hobby , NOW with video !!!!! (Read 17032 times)

Double D · « **Reply #30 on:** October 11, 2009, 09:57:42 AM »

This is what we were using when George cast all the zinc balls.

When George mentioned a better idea, I thought he was describing what Gary made up. I wonder if he meant what you have Max..George?

Cannoneer · « **Reply #31 on:** October 11, 2009, 12:19:59 PM »

I'm glad Max made a post on this thread, because most of us here on the board have seen the exquisite cannons that he has cast. As I was sitting here reading through this thread, I realized that with Max's, George's, (the experience he gained by casting the scale mt. howitzers for the classes he held) and Dan's (thorough investigation and research) combined knowledge of this subject, anyone wanting to explore the operation of founding would have three sources close at hand that could provide good advice on this subject.

1Southpaw · « **Reply #32 on:** October 11, 2009, 02:35:52 PM »

We were only allowed to use aluminum . Lower melting point .
When I moved back home to farm ,the shop teacher in town had put together a foundry set up for the Industrial Arts department . He left the following year . No one with foundry experiencre was ever hired again . There sets the equipment . @ one surplus auction they didn't list it as it cost too much $ for what they would have gotten . I think it is still packed in the back corner of a shed. The Industrial Arts program is long gone . I wonder if I could snoop around and see if I can find it . It was a complete set up . had all the equipment . Natural Gas fired .

GGaskill · « **Reply #33 on:** October 11, 2009, 03:26:02 PM »

My suggestion for a single ended pouring shank for your iron crucible pouring zinc was basically like that second one. The additional idea was to have a pivot point on your casting table so the inside end of the shank could be rested on the pivot while you were pouring so you didn't have to hold all the weight. I can make you some drawings if the words don't make sense.

You would still have to lift the crucible from the burner with the device you have now.

Regarding having a one man foundry, if you have an overhead crane it is possible, but it is better to have another person around in case of accidents to call 911, pull you out of the fire, etc.

Double D · « **Reply #34 on:** October 11, 2009, 03:47:53 PM »

When I work such things alone, Wife and cell phone are my safety team...she won't let me die, she knows she loose 1/2 the retirement annuity if I die. I won't let here help, however, she still goes righty tight, lefty loosy and still can't undo a bolt or take out a screw...

I think I know what mean now , George, but a drawing will clarifiy it!!!

A pouring pivotr might be nice also for helping positioning the mould under the crucible when pouring.

GGaskill · « **Reply #35 on:** October 11, 2009, 05:28:18 PM »

OK, this drawing is no competition with Leonardo but I think it will convey my meaning. The base is a sturdy table about waist high with 3" high edges and a sheet metal bottom (to prevent molten metal from burning the wood.) Fill the cavity with sand to catch spills, etc. The pivot could be made from 1/2" pipe pieces, a flange to connect to the table, a 12" piece as the main riser (adjust length for proper height), a 90° elbow, a close nipple, a 45° elbow, a 2" or 3" nipple and another 90° elbow. The height should be such that the tipped over crucible (a little past 90°) will be almost touching the top of the mould.

In use you will have to swing the shank handle somewhat as you turn the crucible over to keep the pour going into the mould.

Double D · « **Reply #36 on:** October 11, 2009, 06:22:44 PM »

Hey SouthPaw, is this something we could build this winter?

Victor3 · « **Reply #37 on:** October 11, 2009, 07:42:07 PM »

Quote from: dan610324 on October 11, 2009, 12:25:23 AM

it must be close to impossible to have a combo bbq and furnace in the same
but it could be made as 2 different units built together at the same foundation
I will think a little of it and make some sketches tomorrow
you could add a smoker to it also when you are building

but when it comes to iron its a little more difficult , you need a cuppola for that
forget the iron , bronze is so much easier and more beautiful

for what purpose should you have it
what capacity do you need ?? crucible size ??

what size for the bbq ?? 2 sauceages or a whole bull ??

Honestly Dan, I'd probably make the BBQ separate, but put in a forge/foundry in the same area. Kind of an old-time general purpose 'hot stuff' place in a corner of the yard.

It would be nice if I could make bronze items weighing 5# or so; I'm thinking small mortars and handgonnes.

I've only dabbled with sand casting in school, and that was just some simple aluminum parts. Over the years I've picked up some of the basic materials I'd need to put together a small bronze foundry though, and I plan on doing it when I get time.

I understand some of the difficulties with iron and will probably never get into it, but I've always liked cast iron items. Probably something to do with my interest in old machinery...

GGaskill · « **Reply #38 on:** October 11, 2009, 08:05:49 PM »

The usual way of casting iron is with a cupola furnace but it can be done the same way a bronze casting is typically done. You start with cast iron and melt it versus starting with mild steel and coke. You should have more control over the alloy this way.

Don't know any other details of the process.

Victor3 · « **Reply #39 on:** October 11, 2009, 10:38:14 PM »

Cupolas seem like a pain. I don't know that I'd want to try one.

I've got most of the stuff to make up a propane-fired furnace on hand. I picked up a free 14" diameter x 18" high heavy-wall steel hydraulic tank years ago that I figured would make for a nice one. It's got a thick cast iron lid with a hole in the center for the motor shaft, and a fitting welded into the side about 3" from the bottom for the burner. Wouldn't take much work other than adding refractory to it.

Still thinking about maybe making it into a charcoal furnace/forge...

1Southpaw · « **Reply #40 on:** October 12, 2009, 05:35:24 AM »

We could make a suitable pouring device . Just need to think on it for a bit . I think it would be nice to have a stable pour rack with all the assessories .

Double D · « **Reply #41 on:** October 12, 2009, 07:31:43 AM »

Gary, see what you started!!! Good job!

gulfcoastblackpowder · « **Reply #42 on:** October 12, 2009, 12:29:27 PM »

Quote from: RocklockI on October 10, 2009, 02:40:43 PM

how about a Morko gun ?

?

This is familiar. The fellow in the this link (http://www.rvi.net/~djfiron1/AntiquityArms.html) has one of these handgonne advertised (though he doesn't respond to emails), and Fig. 3 on this website (http://homepages.tig.com.au/~dispater/handgonnes.htm) shows an original. http://commons.wikimedia.org/wiki/File:Gun_Sweden_Morko.jpg also shows one in full high resolution - not sure if it's original or a reproduction. I've been looking for a bronze handgonne for a while, and this design is one of my favorites! Wanna cast an extra one?

GGaskill · « **Reply #43 on:** October 12, 2009, 02:13:32 PM »

Anyone know the actual size of this?

RocklockI · « **Reply #44 on:** October 12, 2009, 03:01:17 PM »

7.6"

The model is actual size .

GGaskill · « **Reply #45 on:** October 12, 2009, 03:07:15 PM »

So the bore is about 4 5/8"?

RocklockI · « **Reply #46 on:** October 12, 2009, 03:26:33 PM »

Yes , I guess it is 4 5/8" also , .65 cal.

gulfcoastblackpowder · « **Reply #47 on:** October 12, 2009, 03:29:08 PM »

Do you happen to know the translation of the text on it? I hadn't actually realized it was so extensively decorated with text, until finding the larger resolution picture.

KABAR2 · « **Reply #48 on:** October 12, 2009, 04:24:16 PM »

Translation:

Use ye Blackish Powder Only.

Ye Front towards thou enemy.

Forgive me I couldn't resist.....

RocklockI · « **Reply #49 on:** October 12, 2009, 06:08:41 PM »

Quote from: gulfcoastblackpowder on October 12, 2009, 03:29:08 PM

Do you happen to know the translation of the text on it? I hadn't actually realized it was so extensively decorated with text, until finding the larger resolution picture.

No , not that I'm aware , it is a very old (duh) tounge/ text . Dan told me this so I take it as truth . I am going to duplicate the 'shapes , not the text ' , it should be close . BUT with all this anticipation I cann't get carried away . yet .

btw ,some of the text appears to be gone , lost to the ages ...? (I think it says "BP ONLY" under the barrel

)

BTW I did take 'liberies' on the length of the beard ,it's too long .

Double D · « **Reply #50 on:** October 12, 2009, 06:12:16 PM »

Quote from: KABAR2 on October 12, 2009, 04:24:16 PM

Translation:

Use ye Blackish Powder Only.

Ye Front towards thou enemy.

Allen, Allen, Allen.

Victor3 · « **Reply #51 on:** October 13, 2009, 01:11:46 AM »

I've spent some time the past couple of days looking at various websites, reviving my interest in getting into casting bronze.

I don't have the time to make a full-blown setup right now but I'd like to dabble with something simple, just to try for some bronze ingots. I saw one charcoal setup that used a large stainless stock pot and a smaller pot inside, with the area in between filled with pearlite. I could make some kind of a cover with fire brick.

I think I've got all materials on hand to make a furnace like that, a crucible, tools, ingot moulds, etc. I've also got enough copper cable and tin to make a few pounds of bronze.

I know it would be a disposable setup, but could it work for a few pours? $:-\$

Double D · « **Reply #52 on:** October 13, 2009, 03:59:03 AM »

Victor you probably already know about thus website BackyardMetalcasting.com Some many links on that page, be sure to scroll down and see them all.

Additional information particularly on on burners can be found at Reil burners. So many links on that site, you will get lost. Buried way down in that page is this one Ron Reil Burner

Another site I found interesting is Brians Metalcasting. The step by step pictures are great..

I also picked some Dave Gingery's books from Lindsay's Technical Books I am working on variation of Gingery's Charcoal furnace and Riel modfied Aussie burner. Using contstruction ideas from the others.

KABAR2 · « **Reply #53 on:** October 13, 2009, 06:33:46 AM »

These are from the Recreated Danish village, they show
casting a bronze cannon even though we can not understand
the language the technique is understandable. I tried to load them into the
Realplayer here on the site but could not get it to work.

http://www.middelaldercentret.dk/film/casting1.mov

http://www.middelaldercentret.dk/film/casting2.mov

http://www.middelaldercentret.dk/film/casting3.mov

Here's the website,

http://www.middelaldercentret.dk/Nyheder/nyefilm.html

Results of shooting the cannon:

http://www.middelaldercentret.dk/pdf/gunpowder2.pdf

Victor3 · « **Reply #54 on:** October 15, 2009, 01:17:45 AM »

Thanks for the links guys. I've got a bunch of new bookmarks and can see I've got a lot to learn.

My only casting (sand) was done in ~1978. One item was a forged screwdriver shank with an aluminum handle cast onto it. I've still got it somewhere.

Other than cannons, I'd like to cast bronze handles onto forged knife blades. Good Father-Son project; might even end up with some family heirlooms.

Gary and all involved......... Please keep this thread going and share what you've learned!

Victor3 · « **Reply #55 on:** October 16, 2009, 01:40:27 AM »

Quote from: GGaskill on October 11, 2009, 05:28:18 PM

If you didn't want to build a table, you could make the shank support/pivot with a pointy end on it and just drive it into the ground. You could make it a comfortable height and place your mould on a step ladder or something.

A length of pipe or angle iron with a V-notch cut into the end for the pivot would do.

dan610324 · « **Reply #56 on:** October 16, 2009, 09:07:19 AM »

the posibilities are approximately the same in numbers as there are backyard foundries

RocklockI · « **Reply #57 on:** October 18, 2009, 03:15:18 PM »

here are the results from yesterdays efforts . mike milled it down from the to to reveal a perfectly smooth surface . the smear or smuge appearrance on the lower right is a blurr from the shine..i guess

overall i'm happy with it as the bronze is good . i want to get a little hotter so it flows a bit better .

KABAR2 · « **Reply #58 on:** October 18, 2009, 05:13:35 PM »

I suspect that soon you will be burning out molds to put all this nice bronze you have been refining.

I am looking forward to the end result!

Allen <><

dan610324 · « **Reply #59 on:** October 18, 2009, 05:19:38 PM »

what temperature did you reach this time ??