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The SR&CL Ry foundry, watch our progress

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tomc

Post subject: The SR&CL Ry foundry, watch our progress

Posted: Wed Mar 05, 2008 1:19 pm

Joined: Sun Oct 16, 2005 7:04 pm
Posts: 235
Location: Sw of the Windy City

HI,

We are starting a foundry and needed a burner to warm things up. Found a plan at Lionels Metalcating page and built it. Made it an in-line versis his 90 degree one. Nice blue flame.

Next up is a cart for the furnace and a handle to lift the lid.

Tom C.

Attachments:

Propane Burner overall view 03-01-08.JPG [ 40.96 KiB | Viewed 2419 times ]

Propane Burner shutoff valve 03-01-08.JPG [ 34.07 KiB | Viewed 2419 times ]

Propane Burner air holes 03-01-08.JPG [ 37.12 KiB | Viewed 2420 times ]

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tom_at_srclry_com
Lost somewhere in Michigan!

Last edited by tomc on Thu Aug 07, 2008 7:23 am, edited 1 time in total.

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tomc

Post subject: cart next

Posted: Wed Mar 19, 2008 11:33 am

Joined: Sun Oct 16, 2005 7:04 pm
Posts: 235
Location: Sw of the Windy City

The cart is almost done. Needs lid installed and over center stop welded on. Next up is ingot molds and a pot to melt aluminum in.

Tom C.

Attachments:

Furnace side view 03-01-08.JPG [ 33.02 KiB | Viewed 2419 times ]

Furnace rear lower 03-01-08.JPG [ 46.16 KiB | Viewed 2420 times ]

Furnace lid curing 0301-08.JPG [ 45.54 KiB | Viewed 2420 times ]

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tom_at_srclry_com
Lost somewhere in Michigan!

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tomc

Post subject:

Posted: Thu Mar 27, 2008 3:42 pm

Joined: Sun Oct 16, 2005 7:04 pm
Posts: 235
Location: Sw of the Windy City

We made some crucibles by welding a plate on a pipe and heating and bending a lip with a big hammer. Bolts and a pouring tab were welded in to easy the lifting and tipping. Then I made some ingot molds to hold the metal till it cools.

Tom C.

Attachments:

Crucible closeup 3-15-08.JPG [ 61.11 KiB | Viewed 2418 times ]

Crucibles & Ingot molds 3-15-08.JPG [ 52.8 KiB | Viewed 2418 times ]

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tom_at_srclry_com
Lost somewhere in Michigan!

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steamin10

Post subject:

Posted: Fri Mar 28, 2008 4:52 am

Joined: Sun Jun 08, 2003 11:52 pm
Posts: 4608
Location: NW Indiana. Close to Lake Michigan S. tip

tomc, DANGER < DANGER WILL ROBINSON! ok, oil your molds, after you blast them free of rust. DO NOT pour molten aluminum into the molds I see. They will POP and Explode molten aluminum as you pig out. I have the same forms but they must be FREE FROM IRON RUST, or they will pop and spray aluminum when poured. This is the same system I use, but HEAT the molds to prevent water from condensing on the molds and remove oxides as the AL will react and pop the molds splattering the shop. Ask me how I know. ( GRIN)..

Ya, you got it goin, just do it right to be safe.

Good work, I bid you peace.

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Big Dave

Be Alert! The world needs more Lerts.

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tomc

Post subject:

Posted: Fri Mar 28, 2008 11:57 am

Joined: Sun Oct 16, 2005 7:04 pm
Posts: 235
Location: Sw of the Windy City

Thanks Big Dave. We will watch that closely.

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tom_at_srclry_com
Lost somewhere in Michigan!

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tomc

Post subject:

Posted: Thu Apr 03, 2008 9:31 am

Joined: Sun Oct 16, 2005 7:04 pm
Posts: 235
Location: Sw of the Windy City

We fired up the furnace to drive out the moisture. A few pics.

Tom C.

Attachments:

New furnace under test 03-29-08.JPG [ 43.18 KiB | Viewed 2417 times ]

Tools for lifting & pouring 03-29-08.JPG [ 63.07 KiB | Viewed 2418 times ]

burner on 03-29-08.JPG [ 27.13 KiB | Viewed 2418 times ]

Burner to furnace 03-29-08.JPG [ 58.43 KiB | Viewed 2418 times ]

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tom_at_srclry_com
Lost somewhere in Michigan!

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deltaenterprizes

Post subject: Refractory

Posted: Sun Apr 06, 2008 6:34 pm

Joined: Sat Jan 06, 2007 5:16 pm
Posts: 38
Location: longvew,tx

What did you use for refractory?

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tomc

Post subject:

Posted: Sun Apr 06, 2008 9:32 pm

Joined: Sun Oct 16, 2005 7:04 pm
Posts: 235
Location: Sw of the Windy City

We got the body donated so only made the lid. I bought refractory cement from a brick dealer.
Tom C.

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tom_at_srclry_com
Lost somewhere in Michigan!

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tomc

Post subject:

Posted: Tue Jul 08, 2008 2:26 pm

Joined: Sun Oct 16, 2005 7:04 pm
Posts: 235
Location: Sw of the Windy City

Melting aluminum is fun! Sounds like a good topic. Anyhow, we are busy making ingots from our scrap. Tried a pour to a mold but I don't like the outcome. I am looking for a finer grade as I got sand blasting and is to rough.
Melted some Morton's lite salt for a flux to try. That is in the big saucer.

Tom C.

Attachments:

Ingots and salt 07-05-08.JPG [ 65.41 KiB | Viewed 2422 times ]

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tom_at_srclry_com
Lost somewhere in Michigan!

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tomc

Post subject:

Posted: Wed Aug 06, 2008 12:24 pm

Joined: Sun Oct 16, 2005 7:04 pm
Posts: 235
Location: Sw of the Windy City

Hi,

Now that we have our melting down, We need a beter way to mix our sand. We are starting a mueller. It is sitting on the frame I welded up with the 83 to one gear box we found on Ebay. Below is the tub with the wheel blanks in it, the motor and center support. More to follow as it comes along

Tom C.

Attachments:

muller tub and wheel blanks 07-19-08.JPG [ 36.03 KiB | Viewed 2418 times ]

Muller gear box 07-19-08.JPG [ 56.3 KiB | Viewed 2418 times ]

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tom_at_srclry_com
Lost somewhere in Michigan!

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Andy Rafferty

Post subject:

Posted: Wed Aug 06, 2008 5:27 pm

Joined: Thu Feb 28, 2008 6:28 pm
Posts: 98
Location: Walland, Tennessee

Keep it up Tom,I can't wait to see your castings. Andy

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steamin10

Post subject:

Posted: Mon Sep 01, 2008 2:07 pm

Joined: Sun Jun 08, 2003 11:52 pm
Posts: 4608
Location: NW Indiana. Close to Lake Michigan S. tip

For fluxing aluminum, use HTH pool tablets broken with a hammer into sugar cube size lumps, wrap powder and small pieces in foil, use an infuser cup to add to the melt, skim dross, pour.

Make an infuser cup by making a cup shaped disc with a few 1/4 inch (5/16) holes drilled in a pattern, and weld it to a rod of about 3/8 to 7/16, maybe some 30 inches long. A packet is made with the additions of aluminum foil wrapped onto the edges, and the works plunged into the melt and spin/swished to flux the melt right before pouring. Be decisive with your moves and only take a second or two to move the melt and stand back, away from the fumes.

Warning: the chlorine gas is small but not good for your health so stay upwind and in a vented area. ( a box fan serves for me keeping the breeze going as I bake in the love of a melt.)

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Big Dave

Be Alert! The world needs more Lerts.

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