Large metal foundry project

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swinkdaddy
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Location: Minneapolis, MN
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Large metal foundry project

Postby swinkdaddy » Thu Nov 03, 2011 9:33 am

I am starting to build a metal sculpture sized melting forge (2700°f). For the next couple of months I am building a melting forge, and a wax burn out/shell baking station (1000°f). Later on today I will be moving two 55 gal steel drums into the hack factory. Please don't re-purpose the barrels or stack stuff on top of them. I'll be cutting them down over the next couple of weeks. Then adding lifting frames and hinges to them.

And yes, when I am done. There will be a big pour event. I am planning on casting my own crucibles so there will be one for each type of metal. So start saving up your iron, aluminum and bronze.
Attachments
forge.jpg
Version 3
3 x 3/4' venturi with TWECO 14T Tip Modification
forge.jpg (57.24 KiB) Viewed 2797 times
Last edited by swinkdaddy on Wed Nov 09, 2011 11:12 am, edited 2 times in total.
Have kilt, will travel...

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otto_pjm
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Re: Large metal foundry project

Postby otto_pjm » Thu Nov 03, 2011 6:34 pm

Whoahs, that is big. I'm happy to help make whatever kinds of molds, very excited about this.

Pete

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swinkdaddy
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Location: Minneapolis, MN
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Re: Large metal foundry project

Postby swinkdaddy » Wed Nov 09, 2011 10:54 am

Ok, got a few more things figured out.

In talking to Jude, I am looking at having the whole system ready for a full blown metal pour during mini-maker faire. Given the drop dead date of april 14th. I think the project is totally do able.
found plans for 3/4 inch venturi that work well with a modification of the gas tip. so this is the way to go. its well documented and 100's of them have been made.

I need to make 7 total (2x burn out, 2x kiln, 3x melt) out of 3/4 inside diameter chrome-moly pipe. with 2 inch venturi flair.
the mod is to add a propane tweco t14 gas tip. this creates a far more stable gas flow than a simple pin hole.
Last edited by swinkdaddy on Fri Nov 11, 2011 11:09 am, edited 1 time in total.
Have kilt, will travel...

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swinkdaddy
Posts: 319
Joined: Tue Mar 17, 2009 5:06 pm
Location: Minneapolis, MN
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Re: Large metal foundry project

Postby swinkdaddy » Fri Nov 11, 2011 11:02 am

Thought this was good info anyone could use.
From Dona at Smith-Sharpe foundry supply here in Minneapolis.

KastOLite 26 is $0.85/lb in 55# bags
Mizzou is $0.80/lb in 55# bags.

The 2600 castable requires 86# to do a cubic foot.
The Mizzou requires 141# to do a cubic foot.

Durablanket 2" (equal to Kaowool) is prices at $7.42/SF in 6# density and 2" 8# density is priced at $9.95/SF.

All of these prices are for customers doing foundry work.

The ITC-100 is only available from Axner in Florida.
The closest material we have to do some of the same things is MinroZ, a 62% zirconia material. We sell this by the pound.
The foundry pricing is $3.90/lb.

here is my janky math

3.142 x 144 x 30 = 13573.44
3.142 x 100 x 26 = 8169.2

total vol of 2600 = 5404.24

5404.24 / 1,105 = 5 bags of 55# = $234
-------------------------
koawool#6
81 x 2 / 12foot = 13.5 x 7.25 = $98
-------------------------

3.142 x 64 x 24 = 4826
3.142 x 49 x 20 = 3080

total vol of mizzou = 1746

1746 / 638 = 3 bags of 55# = $132

1 55# bag per curcible = $44
Have kilt, will travel...

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swinkdaddy
Posts: 319
Joined: Tue Mar 17, 2009 5:06 pm
Location: Minneapolis, MN
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Re: Large metal foundry project

Postby swinkdaddy » Tue Nov 15, 2011 4:24 pm

Stumbled across this video of where I have been taking a foundry class. nice reference of the process. and size I am looking at being able to pour.

http://www.youtube.com/watch?v=3r5gEZwurQM
Have kilt, will travel...


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