CASTING A HEADLIGHT HOUSING

This is actually going to be a part for my Cafe Racer but I started I thread here to isolate the casting for those who are just interested in casting. I took pics from start to finish:

Mulling the petrobond sand:



Foundry area ready to go:



Selected a flask that fit:



I am using a bowel for a pattern. Here is the riddle ready to lay facing sand:





Fire in the hole!



I used virgin Wheelium for this casting:





Robert

 

Mold setup and weighted.



Of course I forgot to cut a vent so I had to pull it apart again to do that.

Always preheat your metal:



Poured:



The vent did not fill! That always worries me and you never know if it filled the mold until you crack it open:



Looks good!







The surface finish is OK on the outside which is the important part. It is not perfect and has some sand inclusions. This will not look perfect when polished. I will have to see how it goes. The three supports on the inside were actually cut with a spoon after I pulled the pattern. They do not have to be precise and came out pretty good. I usually do not cut the sand to add to a pattern but it seemed easier this way.

Robert

 

That turned out pretty well.
And those cuts in the sand on the interior look pretty good too.

I like your setup, very orderly and businesslike.
What is the drill on top the beer stein thing?

 

Thank you!
That beer stein is my power riddle. It works great!
It was documented on AA here:
http://www.alloyavenue.com/vb/showt...sive-picture-warning!)&highlight=power+riddle

R

 

Got some machining done:





The best way I know to get the surface finished is to go at it with a flap disc while it rotates on the lathe. I have used this technique successfully in the past. I hope I can take out some of the sand inclusions and get a nice smooth profile.

Then I will machine a bezel to fit over the edge of the glass.

Robert

 

I'm moving in with you! You got a first class setup... AND A LATHE!

Question for ya... I like your blower, I want one! Did you cast that housing? Looks like a DC automotive blower motor and I'm guessing a tree rat cage inside it?? (squirrel) My hokie setup needs some more balls. Specs on that motor would be awesome.

 

That lathe is a very nice piece.

I have started using the vernier calipers on the lathe for depth of cut measurements, etc.
Those things are very handy, and act as a poor-man's DRO.
I bought a number of them last year when they were on sale, and they really work well.

I need to add some to my mill also.

A full-blown DRO would be nice, but I have far more pressing items I need to spend money on.

I found some ceramic sanding sponges (I think that is what they are called), and I use them in a tool and die grinder.
The make very quick work of finishing rough cast surfaces.

I have three grades; rough, medium and fine.
They go on a quick-connect disk (Roloc).
http://www.ebay.com/itm/30Pc-2-Rolo...453201&hash=item33a5ade98b:g:Q84AAOSwjVVVoEVW
These work well for small parts.

Due to the rpm of the die grinder, 2" is as large as I can use in that tool.
If you used them in a slower tool, you could use the larger diameters such as 3" or larger.

For larger parts, a flap wheel may last longer.

 

http://www.ebay.com/itm/NEW-DRO-3-A...087225?hash=item25cd5b1079:g:wuIAAOSw4GVYUPuF

 

I primarily used the lathe to cut the inside supports to fit the lamp. On the outside, I only used the tool on the edge of the housing. It is not a radius cut. It is a simple 10 deg angle. I will blend this into the curved housing with a flap wheel on my angle grinder (theoretically.)

I should note that I have minimal if any porosity due to good control of the furnace atmosphere. I artificially aged the casting as well. Still, it machines like crap compared to T6 treated stock. I considered T6 treating this but the soak temp is so close to hot short I thought I would ruin the casting.

My blower is a 120v squirrel cage from a standard gas home heating furnace. I think they call it a draft inducer? I cast the housing for the propane injector. It will also run as a Reil burner without the fan. When doing brass, I need the fan.

Sorry to keep linking to AA but there is a lot of info documented there:
http://www.alloyavenue.com/vb/showthread.php?7953-Reil-Blower-Combo-Burner&highlight=reil
R

 

thanks robert. i have one of those on the bench. i need to revisit that idea soon.

 

Bezel made from sheet extrusion:







R

 

That's a sexy looking light Robert!! It's going to look right at home on the front of the bike.

CBB

 

It polished up very nicely. Almost zero defects visible. The sand inclusions sanded out and there is no porosity.







Mounting TBD. Still trying to figure it out.

Robert

 

That turned out nice!

 

That is a beautiful headlight. Nice work!

 

Agree with the others, beautiful work.

Has the bike got a rear light?

 

Thank you and Yes! These rear lights are awesome:

 

I am looking at this seat:



The rear edge of the seat is nearly straight so I am thinking I could add an aluminum extension to mimic the look of the cafe racer seats but keep the functionality of a bicycle seat. Thoughts?

Robert