flat belt pulley pattern

[DaveH]

David,
I think that would look good on my dining table.

DaveH

[dallen]

I said in a video that I'm not a carpenter, or a cabinet maker, or pattern maker, but I want a single speed pulley on the Cincinnati so the only way I have of getting one is to make this pattern that you guys have put up with me posting all the photos (I know how Ed like's pictures). No its not a work of art, you have to get TomG for that from the woodwork I've seen from him.

This is hopefully only going to be used one time and who knows maybe in a hundred years someone will find it and say, Hey look what some Redneck cobbled together.

This is going to probably be the last of the pictures where it looks sorta pretty, from here as soon as a knock together a flask out of something I will try to ram it up, I think I have a smooth enough finish on it that it will pull, but the only way to know is to bury it in some sand and try to get it back out.

And I'm also tired of sanding on the damn thing.

I really didn't know if I would be able to pull this off or not, the only wood working tools I have are a hand saw and a skill saw, I used my neighbors table saw, and borrowed a miter saw from a buddy to do this with.

I do want to thank everyone that has commented on it.

I have a couple more pieces that I want to make for the shaper, one is the crank I don't have one, and there is suppose to be a hand wheel on it that is used to position the ram its missing so I still have some work to do after I see if I can cast this I have and A20 which should be plenty big but may have to have a smaller one on hand to feed the shrinkage, won't know on that till it happens.

[doubleboost]

That is one hell is a nice pattern you have built
This link should take you to the wax block I use

http://www.ebay.co.uk/itm/600g-Yellow-Wa...35c53e8135

Good luck with moulding and casting it
John

[TomG]

That looks great David. Excellent work

It looks to me like all of the wall thicknesses are pretty consistent so there shouldn't be much sink as long as you can keep it filled as it cools. If it's all sealed well, you may be able to calculate the volume by seeing how much water it will displace. That way you'll know for sure how much metal you'll need.

Tom

[dallen]

Thanks John, it also gave me one hell of a head ache making it. I will do some searching and see if I can find a similar product on this side of the pond.

Tom your right most of the parts are about the same size, the gussets do vary in thickness from one side to the other, the web where the thing splits in half is about a half inch in thickness. the rim is pretty close to the same but the only problem there is being taken care of by the gussets venting the top edge so it will fill ok, I'm wanting to put a core in it just to see if it will work out ok, but that leaves a big problem with the center hub shrinking really bad, there are a couple of things I can do one it to go ahead and put in the core but also put in a couple of risers to feed the thing as it cools and make them open so I can add more hot metal to them to keep them open and hot.

The other is to put in a couple of risers around the rim and let them feed it I have some Exothermic riser cups that when the hot metal fills them they will burn hot enough to melt aluminum so they will also provide plenty of hot molten metal to feed the casting as it cools. damn good thing I got more then two of those cups.

Anyway its going to be a crap shoot either way I go with it, but like they say first time for every thing.

As of this moment every surface is sealed except for the two faces of the plywood that face each other, but a coat of paint will take care of that. would use primer but most of its not waterproof. so yes I can dunk the thing in tub to find out how much metal I will need for it.

Have a Doctor's appointment in the morning, then it will be on to making a flask I figure its needs to be 16 X 20 X 11 deep so each halve is going to be 5.5 inchs deep. THIS IS NOT a ONE MAN POUR

DA

[stevec]

DA, did I mention you have oft said "but where's the fun in that?" I must have been mistaken.

[dallen]

the funs gonna leave when I have to start wrestling the drag and cope around on the bench, flask that big will probably take close to 300 pounds of sand.

other wise I've had a lot of fun making the pattern and learned a few things I should of already knew but didn't.

The real fun will be if I can take this to the lets pour it in Cast Iron, which I doubt will happen as I don't have a crucible big enough to do that without ruining the one that I have for anything but Cast Iron.

Oh almost forgot to mention your welcome to come help gonna need some strong backs for this one.

[Mayhem]

Probably a silly question - but could you pour it in two parts and then bolt it together?

[dallen]

As Steve say's I have a habit of saying Where's the Fun in that,

It could be done but wouldn't look very nice if I did it that way with this pattern. I guess a guy if he wanting different speeds could make a hub that you could change out the rim on, it doesn't run fast enough to need balancing. and you could by making a new pattern make it look pretty good. I just had a passing brain wave that I will have to see if I can drag out the Big Chief tablet and Crayola's and try to put it on paper so to speek, it may actually be a good way to go.

[Mayhem]

I was wondering if it may have been an option given you don't have the capacity to pour that much cast iron in one pour.