Lost foam casting Mon, 18 May 2026 13:27:58 +0000 Mon, 18 May 2026 13:27:58 +0000 The Home Foundry http://forums.thehomefoundry.org/index.php?forums/lost-foam-casting.14/ Thu, 30 Apr 2026 15:42:10 +0000 http://forums.thehomefoundry.org/index.php?threads/reuasbale-offset-pouring-basin.688/ http://forums.thehomefoundry.org/index.php?threads/reuasbale-offset-pouring-basin.688/ invalid@example.com (Al2O3) Al2O3
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This is the material used for the basin.

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I used it for the first time today. I wanted to use it on familiar casting so I experimented with one of my automotive water necks...

Reuasbale Offset Pouring Basin]]> 82 Tue, 10 Mar 2026 19:51:38 +0000 http://forums.thehomefoundry.org/index.php?threads/sbf-inline-carb-manifolds.3086/ http://forums.thehomefoundry.org/index.php?threads/sbf-inline-carb-manifolds.3086/ invalid@example.com (Al2O3) Al2O3
I usually make the intakes for vintage Ford performance engine platforms. I've had a number of inquiries about intakes for these combinations as they are popular and often more economical builds...

SBF Inline Carb Manifolds]]> 5 Tue, 24 Feb 2026 23:05:59 +0000 http://forums.thehomefoundry.org/index.php?threads/1-4-scale-v8-engine-427-sohc-cammer.3099/ http://forums.thehomefoundry.org/index.php?threads/1-4-scale-v8-engine-427-sohc-cammer.3099/ invalid@example.com (Al2O3) Al2O3
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A friend who is a model engine builder asked me if I...

1/4 Scale V8 Engine - 427 SOHC Cammer]]> 23 Wed, 21 Jan 2026 15:51:16 +0000 http://forums.thehomefoundry.org/index.php?threads/cant-find-fine-sand-for-lfc-help.3090/ http://forums.thehomefoundry.org/index.php?threads/cant-find-fine-sand-for-lfc-help.3090/ invalid@example.com (R Flego) R Flego I'm new to Lost Foam Casting. I've accumulated almost everything to give it a go except for the Fine Sand.

Kelly said to get Commercial Fine Sand. But I cant find it anywhere. Sakrete and Quickrete used to sell them at Lowes and Home Depot but no-one carires it anymore. Quickrete I think stopped making it. Does anyone have suggestions for a suitable alternative or where I can find Fine Sand?

Thank you all!

Roland]]> 8 Tue, 04 Nov 2025 01:54:19 +0000 http://forums.thehomefoundry.org/index.php?threads/asking-for-a-new-kelly-video.3066/ http://forums.thehomefoundry.org/index.php?threads/asking-for-a-new-kelly-video.3066/ invalid@example.com (CFFDave) CFFDave
In some of Kelly's videos I see a suspension rear upright. I want to cast some for my Formula Ford as it is long ago out of production.

Any chance you'd post a video about that project?

Some questions:
How to prevent shrinkage defects in the heavier sections?
How to get sand to fill the area that was a core on the...

Asking for a new Kelly video]]> 3 Thu, 30 Oct 2025 19:15:38 +0000 http://forums.thehomefoundry.org/index.php?threads/my-first-lost-foam-casting-close-oh-so-close.3056/ http://forums.thehomefoundry.org/index.php?threads/my-first-lost-foam-casting-close-oh-so-close.3056/ invalid@example.com (Guitar Bill) Guitar Bill I poured at 700C using my new digital K-type unit.
As you can see, the aluminum didn't quite make all the way down.But close.
The rest of the casting is perfect aside from that.

The funny knob on the backside is a knuckle, a separate part.
Now to figure out what I did wrong.
I put the tin pan on a slight downward angle to match the filler.

I liked how well the compound help up...

My first lost foam casting. Close oh so close.]]> 44 Thu, 30 Oct 2025 18:43:01 +0000 http://forums.thehomefoundry.org/index.php?threads/managing-h2-porosity-in-hobby-aluminum-casting.3063/ http://forums.thehomefoundry.org/index.php?threads/managing-h2-porosity-in-hobby-aluminum-casting.3063/ invalid@example.com (Al2O3) Al2O3
No...

Managing H2 Porosity in Hobby Aluminum Casting]]> Mon, 27 Oct 2025 13:02:51 +0000 http://forums.thehomefoundry.org/index.php?threads/spreadbore-carb-adapter.3062/ http://forums.thehomefoundry.org/index.php?threads/spreadbore-carb-adapter.3062/ invalid@example.com (ESC) ESC The adapter has to have splayed ports so lost foam was the...

Spreadbore carb adapter]]> 2 Wed, 15 Oct 2025 15:04:14 +0000 http://forums.thehomefoundry.org/index.php?threads/no-styro-cups.3055/ http://forums.thehomefoundry.org/index.php?threads/no-styro-cups.3055/ invalid@example.com (Guitar Bill) Guitar Bill No-one carried them.
I went to , Wal-mart, Giant Tiger, Canadian Tire, Zhers, Dollarama and not one of them carried it. My last try was an independent dollar store and found these crafters cones. They came in different sizes and gabbed these. I will cut the small end to match the spout and hollow them out somewhat. View attachment 26016

Necessity is the mother of invention,...

No Styro Cups???]]> 8 Tue, 07 Oct 2025 17:43:36 +0000 http://forums.thehomefoundry.org/index.php?threads/thin-walls-casting-failure.3039/ http://forums.thehomefoundry.org/index.php?threads/thin-walls-casting-failure.3039/ invalid@example.com (3gger) 3gger I was doing alum castings for quite a long time, mostly lost foam type. Nothing fancy, just sqare'ish or round'ish parts like pulleys or mounting blocks.
Recently I was trying to cast thin walls item - step motor bracket - and it was a failure.

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Was it cold aluminum ? something with the sprue ? Appreciate you input.

P.S. part should be something like that, not exactly but close...

Thin walls casting failure.]]> 26 Tue, 19 Aug 2025 20:51:00 +0000 http://forums.thehomefoundry.org/index.php?threads/hotwire-intake-manifold.3028/ http://forums.thehomefoundry.org/index.php?threads/hotwire-intake-manifold.3028/ invalid@example.com (rocco) rocco
]]> 3 Wed, 23 Jul 2025 11:54:45 +0000 http://forums.thehomefoundry.org/index.php?threads/sprue-placement.3024/ http://forums.thehomefoundry.org/index.php?threads/sprue-placement.3024/ invalid@example.com (dom) dom
I am having issues with casting aluminum. The piece is very vital for my cnc machine Y drive axies.

I am unsure where to put the sprue. I had it on the outside, on top. Flipped the model over and put a sprue from the top to the bottom diagonally. even tried to vent. I am just not sure what I am doing wrong.

Ive tried pouring around 680c, 700c, 740c was the best pour but lacked enough metal. But not sure why i was missing a middle piece.

What temp...

Sprue Placement]]> 10 Fri, 18 Jul 2025 19:29:38 +0000 http://forums.thehomefoundry.org/index.php?threads/more-boss-429-intake-manifolds.3000/ http://forums.thehomefoundry.org/index.php?threads/more-boss-429-intake-manifolds.3000/ invalid@example.com (Al2O3) Al2O3
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Also have a couple lids to cast too, one for a CrossBoss...

More Boss 429 Intake Manifolds]]> 13 Wed, 25 Jun 2025 17:35:12 +0000 http://forums.thehomefoundry.org/index.php?threads/gating-lost-foam-cylinders.3017/ http://forums.thehomefoundry.org/index.php?threads/gating-lost-foam-cylinders.3017/ invalid@example.com (Tops) Tops @Uglydog, 2.25" diameter x 3/4" bore x 11.25" to be lost foam cast in Alu. Parts to be turned down and threaded before use.

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-does the 1 x 1.25" sprue look feasible for a near vertical or vertical pour?

-any merit in packing the centers with loose sand or Petrobond in case compaction is less than ideal?

Hoping to coat today and cast tomorrow, thanks!]]> 6 Mon, 19 May 2025 13:17:12 +0000 http://forums.thehomefoundry.org/index.php?threads/saucer-cup-spoon-%E2%80%93-the-lost-foam-edition.1020/ http://forums.thehomefoundry.org/index.php?threads/saucer-cup-spoon-%E2%80%93-the-lost-foam-edition.1020/ invalid@example.com (Al2O3) Al2O3
https://forums.thehomefoundry.org/index.php?threads/my-new-lost-foam-casting-rig.516/#post-24052

…….so like the title says, I chose the old saucer, cup, and spoon. As many of you probably know, it was sort of a right of passage for molders.

There were a couple reasons I selected this and before HT1...

Saucer Cup & Spoon – The Lost Foam Edition]]> 60 Thu, 15 May 2025 19:13:00 +0000 http://forums.thehomefoundry.org/index.php?threads/pipe-saddle.2911/ http://forums.thehomefoundry.org/index.php?threads/pipe-saddle.2911/ invalid@example.com (FishbonzWV) FishbonzWV View attachment 24782


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Broke my favorite ingot mould by pounding it on the concrete to release the ingots.

View attachment 24785]]> 9 Tue, 06 May 2025 01:01:22 +0000 http://forums.thehomefoundry.org/index.php?threads/lost-foam-failures.2990/ http://forums.thehomefoundry.org/index.php?threads/lost-foam-failures.2990/ invalid@example.com (Dan Dubeau) Dan Dubeau
The first failure was 100% my fault as I didn't have enough sand to completely cover the pattern, and made a hasty decision to make a secondary containment tube out of...

Lost foam Failures]]> 6 Sun, 27 Apr 2025 23:19:19 +0000 http://forums.thehomefoundry.org/index.php?threads/glue-for-foam.2981/ http://forums.thehomefoundry.org/index.php?threads/glue-for-foam.2981/ invalid@example.com (David427) David427 33 Tue, 22 Apr 2025 22:53:36 +0000 http://forums.thehomefoundry.org/index.php?threads/casting-a-boat-steering-adapter.2703/ http://forums.thehomefoundry.org/index.php?threads/casting-a-boat-steering-adapter.2703/ invalid@example.com (FishbonzWV) FishbonzWV One of the upgrades will be a rotary steering system. The old cable steering system had a 15 degree tilt built in because the dashes were flat. Most new boats have the tilt built into the dash so the rotaries are a straight shaft. I needed to make a 15* wedge to get the wheel out of my lap and be large enough to cover the holes from the old mounting.
Carved a couple 5" x 3/4" disks out of XPS and glued them together. My 9"...

Casting a Boat Steering Adapter]]> 20 Mon, 07 Apr 2025 17:19:29 +0000 http://forums.thehomefoundry.org/index.php?threads/successful-pour-kids-widgets.2977/ http://forums.thehomefoundry.org/index.php?threads/successful-pour-kids-widgets.2977/ invalid@example.com (Mburtis) Mburtis
Anyway, today I cut out a couple of arrowhead foam shapes and poured them so they could see the process and I could experiment with lost foam some more. They turned out pretty good.

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