I have been watching Kelly's videos and am very impressed. I learned sand casting more than 50 years ago but I think lost foam would be good for my projects in this century. 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 original parts? Getting a refractory coating I understand, but getting that area full of sand looks impossible. BTW: I like the way you did the inverted-funnel fill-sprue. Here's what I want to make. The contrast washes out some detail, but the upper part is an H section and the lower is hollowed. Obviously made by sand casting in England back in the day out of magnesium. I'd make out of aluminum as I know nothing about casting magnesium and I think it would require things beyond my scope.
Hi Dave, It's not a video but plenty of pictures. Have a look here and we can discuss it further. Automotive Rear Upright/Wheel Carrier | The Home Foundry This was seven years ago, and you can surmise it was far from instant success. I have to say, I could make a much, much, higher quality casting of that part today using lost foam method. Today I'd use my cnc router to make the pattern in two pieces. As/if you read through that thread, you will see some cautions from a pro-foundryman. Those cautions are well founded for a critically stressed part like this. I've made so many process refinements since then. I don't use those conical foil sprues anymore. I use these now and they are a marked improvement. Reuasbale Offset Pouring Basin | The Home Foundry I don't know where you are at in the journey of developing your home foundry equipment and processes, but if it is early days, I suggest a few simpler projects to get your feet wet. I'll be here to help if/when needed. Best, Kelly
Thank you very, very much. Your generosity with information is appreciated. There are a couple commercial, low volume sand casters near me that service the automotive industry. I'm hoping to tour one of the facilities soon. It seems they are mostly doing 3d sand printing and air-set sand when not printing. Very cool stuff. I doubt I can afford them, but you never know. Maybe they'll find it interesting and have pity on my wallet.
It's worth doing just for the learning experience. If you can strike up a friendship there, it can yield many benefits like access to good alloy and professional foundry materials. 3D sand printing can be pricey but prices have become much better more recently. If you have time, develop the knowledge, and have the desire, it can be done at home. Sort of the motivation behind my videos......and it keeps me out of the bars! Best, Kelly
