Mill Engine Cylinder Casting

[doubleboost]

(08-13-2012, 07:19 AM)TomG Wrote: Nice work John. It's been a long time since I've had the fun of machining a casting.

I assume by the blackening around the casting, that you use an oil tempered sand? Is it your own recipe or do you buy it already mulled. And what about flux? I know chlorine type degassers are used for aluminum, but do you also use some sort of flux for the bronze?

Tom

Hi
Tom
I used "petrobond" oil based sand to face the mould backed up with green sand
With clean bronze i dont use a degasser
Even with aluninium if you just stirr it well it seems ok
The commercial de gassers give off real nasty fumes
John

[doubleboost]

Hi
Lads
Did a bit video of my sand cores and cylinder casting
This should give you a laugh
http://www.youtube.com/watch?v=2VnqOhvLu...e=youtu.be
John

[DaveH]

John,
Just watched your video - bluddy fantastic mate.
And I have just watched it again.
It is certainly going to get my vote for an Oscar
Congratulations on a fine and very informative video

DaveH

[doubleboost]

Hi
Lads
Got a bit more machining done on the cylinder
Next job is to mount it on the lathe saddle & poke a hole through it






John

[EdK]

Nice video John! I was enthralled watching it.

Ed

[DaveH]

Looking good John.

DaveH

[ETC57]

Awesome video John

this is a great project looking forward to the next step

Jerry.

[f350ca]

Looking real good John. Hope someday to try my hand a casting, to many projects too little time.
Curious, why wouldn't you bore the cylinder on the mill?

[doubleboost]

Hi
Lads
Started boring the cylinder
Mounted on the lathe saddle
Body filler is used to plug the end and the centre marked
It is mounted on the face that it will sit on
This should keep the bore paralell with the base


The bottom of the cylinder is held against the face plate this should keep the bore and the botton face in line (note use of tab papers) as a "slip guage)



After a few cuts it was obvious that something was wrong



Sand inclusion in the casting (core sand)



I may as well keep going





Cleaned up at just under 2 1/4 inch


Should be ok with one more fine cut when it cools off

I was aming for a bore of 1 7/8 the same as my marine engine

2 1/4 will give it a bit more power
John

[DaveH]

Nicely done John
Sad about those inclusions but you seem to have sorted them out

DaveH