REPRODUCING AN IRON CASTING FOR A 107 YEAR OLD CHEVROLET. BRAKE FLANGE BACKING PLATE.
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- Опубліковано 20 тра 2021
- This video illustrates the techniques involved with producing a casting for a vintage 1914 Chevrolet. Using a vertical core through the center, I ram this in a second attempt that is successful for my customer who I introduce at the end.
#windyhillfoundry #madeinmississippi #1914 #Chevrolet #castiron #ironpour #grinding #suhner #restoration #royalmailcar #mississippi #melt
Abrasives and grinder provided by SUHNER INDUSTRIAL PRODUCTS LLC - Наука та технологія
Clark, this is Ray Moot, owner of the car you made the part for. I want to publicly thank you and your wife for agreeing to pour this part for Steve and I. I also want to thank my friend Steve for not only doing all the research about this and finding your Windy Hill business, but following this project through and also bringing it to you, watching the process and picking it up on his way back. He is now doing an amazing job machining your outstanding casting to match the original 1914 Chevrolet part we needed to reproduce. It will allow us to get the rare 1914 Royal Mail Chevy roadster back functional again. Your casting is of high quality and a real piece of art. Can't thank you enough.
Ray
Thanks for the kind words Ray and the pattern work made all the difference 👍. Glad I was able to be a part of this restoration and hope to get by there and see this once the car is complete.
In this video, Clark showed the first casting as being externally pitted. Is there any reason that part could not have simply been welded? You stated that this part wouldn't really be seen. So, aside from aesthetics, I am assuming the only other factor would have been a failure due to the torsional forces it would experience (as this is essentially a brake drum assembly) ...any insight as to whether or not that part could have simply used in its pitted form or been welded and meet spec? In other words - was that first casting truly a write-off?
Also, this seemed to have been made of/forged from old disc brakes. Are the "self-lubricating" properties of cast iron relied upon for slippage or was there a brass sleeve (or similar) installed in the "bushing" (maybe that is actually what the press was showing)? Or does this part never contact the axel?
Beautiful vehicle BTW. It's even more so to see two passionate people bringing their talent together to breathe new life into it. Thank you both for sharing!
@@secondarycontainment4727 Sad Sadif, the casting most likely would work as for function but as much work as will be performed to bring this car back to it's near factory state, I can't let a casting go out looking like that when I know I can make improvements next pour. I always anticipate a casting will have to be done twice, often that's not the case but did work out that way this time. In summary, I expected to have to do this again as with any one off work. Thanks by the way👍
Lots of us old machinery lovers would really like to see this project as it progresses!
I
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I love the fact that you point out examples of cause and effect on real products. I'm a hobbyist and I always learn from your work. Showing that narrow shrink crater where that riser was was a great teaching opportunity and you didn't fail to grasp it. Well done as always, and thanks very much.
Thanks👍
As a pattern maker for the past 35 years I really enjoy these kinds of videos. For me it's all computer design now, but I started out making wood patterns. When I was an apprentice I had to do work like this in my foundry class. We did several different parts but the one I remember the most was making a pully wheel with a green sand core. I like the recycling of the brake rotors. I've designed a lot of rotor patterns and core boxes over the years.
Bob thanks for the reply. It's always fascinating to hear from others like yourself who did these things. Most people don't comprehend what cores are or how they are planned
That's awesome. Glad you were part of restoring this piece of American car history.
Thanks👍
I know that Jay Leno makes a lot of parts for his collection (especially his steamers), and uses his 3-D printer a lot to make the blanks. I also recall the people who now own the original Stanley Steamer name actually gave him a placard proclaiming that he was an 'authorized repair shop' (not bad for a brand that has been out of business for nearly 80 years!). Nice to see people with some SKILLS doing things like this!
Thanks Fooman, feel free to share this to Leno if you have his contact.
@@windyhillfoundry5940 I am subscribed to his channel, not sure if he accepts comments, but if he does I will forward it!
My father worked in a foundry for over thirty years. This is awesome seeing the process of making a casting from scratch. He used to tell me how it was done when I was just a kid, but seeing it takes me back to those days. You do excellent work!
Thank you Rich. Your father had a lot of fascinating things to tell about I'm sure.
Still. its so very nice to watch a master and work preproducing something like this. You are a time machine sir.
Thank you👍
Just beautiful!
That looks like some high quality casting sand.
You are without doubt a fine example of a man that takes pride in his work!
Cheers from John, Australia.
Thank you John, very kind of you👍
I am always impressed with the quality of the iron castings which you produce, using equipment which would not have been out of place a century ago. I certainly enjoy watching your process of producing castings.
Thank you David. I've always been a firm believer that anyone can make anything without the need for state of the art machines and equipment 👍
Also the irony of modern disposable brake parts being recycled into a replica of a 107 year old part that can easily last another century due to your foundry skills is just an amazing reality to see.
I have no connection to this "world" but I love watching the process
Amazing.
I love the brake rotor crusher! No safety gizmos or warning signs showing a stickman being wounded by unsafe actions.
Thanks👍
This is super cool, thank you for the video!
Glad you enjoyed it👍
Well done Clarke! As usual! I was fortunate to attend a small Junior College back in the 70's and we did bronze casting! Great experience.......
My dog loves to ride. Good video.
Thanks Mike👍
Great video. I admire your perssistance to get it right. Thanks for sharing your skills.
Thanks Mike👍
Great content thanks for sharing
That last casting turned out amazing ....Thanks Clark & Wife.....Hope u'all are doing well....!
Thanks Steve👍
I love seeing the one offs to restore something that otherwise could not have been possible with out years of searching for parts. Thanks for sharing
Thank you digitizer👍
I worked in the printing industry as an engineer and designed printing press accessory equipment which required casting drawings I enjoy watching you form the castings so glad you got all your equipment back up and running
Phillip Jones > Would you know, where to find old / traditional / "not-modern" printing equipment?
*are doing old-school-work-shops as part of coaching handy-man-humans back to life, after serious traumas* >@< aktiveungeamputerededk@gmail.com
Regards Jens
Very interesting. I would love to get my hands on some 1850's era flywheel drawings
You are amazing...incredible work.
Thank you👍
for a random video that popped up in suggestion, this was a great watch, thank you for recording and uploading it.
God bless you Windy hill Foundry. Recreation of history👍
Thank you Jerry👍
Very impressive
Another amazing casting.
Thank you Misterbones👍
I truly wonder how many trucks, tractors, cars and machinery in general are operational today on the farm, road or museum for us modern folks that pieces and parts on them were recast by fine skilled gentlemen like yourself. Thank you Sir and to all of your colleagues the world over, a thousand times, thank you.
Art
Thanks Art, if it was done before it can be done again👍
Nice job 👍
Lovely! (And it's made outta better steel than the original could possibly have been.)
When I began my career in 1970, there were probably around 1500 small, family-owned gray iron foundries in the US. Windy hill is probably one of the few remaining - thanks for keeping the technology alive.
Thank you Cabby Hayes👍
Thank you.
Clark, what an interesting project. It combined three areas of interest. Antique cars, recreating castings, and machine shop techniques. Thanks for sharing.
Thanks for watching Rex👍
Very satisfying project, cheers!
Great job Clarke!
Thanks Michael 👍
Great work.
Thank you👍
cool i found a nice channel be blessed man
I am not an engineer, but it is so refreshing to see someone using skill and artistry - and a love for what you do. Really interesting, and it is clear you really enjoy this work.
This type of project is as close as one can come to "time travel", the old ways many times have their advantages, in this case Clarke you keep those old ways current when you take on a casting to create, it's impossible to put in to words just what it takes to keep all the nuances in play to produce superior results.
All too often I read how people trivialize the craftsmanship, skills and good old savvy used to produce these superior results, Windy Hill Foundry is building a legacy one fine casting at a time while providing a source to keep old machines in service, you are destined to become a legend Clarke.
Love the true respect for genuine craftmanship, being retired tool maker
(But active Life Coach, guiding free from / out of Victim Mentality > Would be honered to learn from you.)
Merlin, I am speechless. I really appreciate that. I want to frame this one😁
Clarke may not realize it but he's already a legend for those of us in the maker world. We all wish we were half as good at mold making!
Thanks for sharing! As always, great work.
Thank you Craig👍
Awesome project. I really like the fact you are an American foundry, as there seems to be so few now days!
🇺🇲🇺🇲🇺🇲
Very nice Iron Work Clark. I am very impressed. Thank you for sharing.
Take Care and Stay Safe.
Bob
Thanks Bob👍
A labor of love! dollar and buddy look real healthy. Always enjoy your exacting work. Thanks for the look.
Thanks John👍
That grinder and them discs look good Clarke...
And that casting....good
Thanks Glenn👍
That was a beautiful piece of art, and the process was fascinating. The fact that it will result in the restoration of that car makes it quite a special project.
👍
What a great project. Great to see parts being made from scratch.
Two nice blokes working together :)
Thanks Davo👍
Used to hang around foundries a lot in my younger days when I still worked as an engineering patternmaker. They were always fascinating places - hot, dirty and primal. Thing is though, nobody ever talks about what the pattermaker did so as a mold can be made, but it's great to see those processes again.
I agree Simon, I developed a whole new respect for any foundry related position once I got involved and when I think of designing patterns, gating systems, building the patterns and core boxes, it is overwhelming
Great project Clark. Thanks for sharing.
Thanks Michael👍
Your wife is literally Iron Woman! You cracked me up @11:24 with those bellows. Thanks Clarke!
Just curious if anyone took that seriously😁
For a split second y'all got me I can admit it lol
Braking systems sure have changed since 1914!
Great casting job!
Thanks and yes they have👍
I always enjoy seeing your work. You can be proud of the quality of the iron based on those pictures on the lathe.
You’ve got the sand building down pat. I try to visualize what you’re doing, but I get lost every single time. Then I see the results and it all makes sense.
Thanks again.
Thank you 👍
"That suckers done." Excellent work!!!
Thank you👍
Cool dogs !
They are cool until they bark at 2AM😖
Another great job, Clarke! When you removed the riser the quality of the iron was evident... solid with no porosity!
Thank you Roger, the first one would have been a success but there was some subsurface dross that went down the sprue near the end😞
Great casting. I always enjoy watching you work. Keep on keeping on.
Thank you Harold👍
I just realized Suhner was founder the same year as that car came off the factory line! Small world.
Beautiful work Clarke. It must be very satisfying to help restore an antique by making parts that are no longer available.
Thanks Dom and yes it's very satisfying to be a part of something like this👍
Great to see this! I hope the big foundry gets fixed up easily.
Thanks, hopefully we get it relined soon. Until then I'm using the road furnace I use for demonstrations👍
I cannot believe you do not have 100K subs. You deserve to have that many - love your channel.
Thank you Eric, please share my channel any chance you get. I just said if I get 100k I will crush an engine, with it running😁
I just found your channel and subbed . I just love seeing this process take place .
👍
Nice job man.
Thanks Bruce👍
Outstanding. That is a pricey grinder, definitely a good investment
Tab I'll never go back to what I was using after getting this. It significantly reduces grind operations and at slower speed throws off heavier particles that would normally float in the air. I breath better😁
Great video and great casting 👍
Thanks Arnold👍
Nice job!! Congrats!
Thanks Elias👍
Nice casting. Great core treatment.
Thank you 👍
I like you, you're funny. I liked seeing how the part was used on the vehicle.
I was puzzled myself until he provided the pictures👍
Very neat, thanks.
Thanks Tom👍
Hey Clark, looks like I need to visit you sometime and help get some electrical things sorted out for you... Great work that you do, definitely admire your skills and abilities.
What a cool project to be a part of.
I know right, hoping Leno sees this. I'm sure he could use me at times
Next time I need a grinder I’m buying a Suhner. It allows you better control without loss of power at low RPMs it appears. Cool to see you helping to restore some auto-americana.....
Thanks TJ and yes this grinder can take really aggressive cuts which mean heavier particles that don't float around
The accent makes it 100% better
Thanks for watching 👍
Love the alternative approach! 8)
Wonder how many will try that😁
Almost a lost art. Thank You for sharing your amazing craftsmanship. Do you have someone who makes 3D printed forms for your casting? Adam Booth steered me your way.
Thanks Sean, all the patterns are supplied by the customer. Not sure who they use to print these if not their self. Keith Rucker always supplies what he prints when he doesn't make these out of wood.
Another great video! I would like to see more about that product you used to make the core.
Vincent I will remember that when I do another one on cores👍
Love the view...
Thank you Randall👍
I've got that exact same model of weighing scale.
Of course, mine's only used in the kitchen. 😊
Great job Clarke. Got to Keep the old chevy on the road
I want to drive that thing when they get it rolling
Great little video, and an excellent outcome! :) Thank you, also, for working in metric. Another cheers from Australia :)
👍
Daaaaaaaang! Kudos from West Virginia.
Thanks Rob👍
Just subscribed...
Great work Clarke. Your sand always looks really dry, but it compacts beautifully. Regards, Preso
Thanks Mark and yes, the moisture content is very low but plenty once rammed👍
we should totally do a kickstarter to get you a replacement furnace
Thanks Andy, unfortunately I have to build mine. The ones available are basically designed for non ferrous use. They say you can melt iron but based off those designs, I believe these would melt down in a month or so the way I run them. I am currently using my road furnace as we re line the big one.
@@windyhillfoundry5940 good luck and if you need volunteers to run the air hammer I'll come see you :)
@@GooseYArd 👍
I WILL HAVE ALL OF YOUR KNOWLEDGE NOW PLEASE
Somebody said tot up in here too.
Are we all family now?
Years ago, I was doing some work in the Honda V-tec engine block foundry. I was amazed at how many castings fail inspection, then get sent back for remelt. Just my 2¢, UA-cam decided I need to know more about casting at 05:30?
I have a lot I scrap out here as well. It's usually very little flaws that probably would function just fine but my conscience won't let it ship if I know I can do better
you would think this guy knows what he is doing.. hahhaha... dude got game and skill.. good job
I catch myself saying the video titled doesn't look interesting and I think about not watching it. but every time I watch it I regret thinking that. Nice work on the cast. You make great video's!
Thank you Joe, I appreciate that👍
@@windyhillfoundry5940 no problem. In a very honest and serious question do you have the ability to make a cast of donal trumps head? I know this is out of left feild but id pay for it. Lol
@@pitviper1942 Joe to do anything like a bust or head I would really need to do it with lost wax process to make it turn out right and that would require sculpting which I can not do unfortunately
@@windyhillfoundry5940 no biggie. Thanks for letting me know. Ill just look forward to the next video!
from what i understand of it the patterns for some of these old parts can sometimes be harder to find than the part itself although this issue would definitely have lessened in the years since 3d printing became commonplace
Nickolas, yes, most patterns are obsolete after one generation let alone 3 or 4.
when i went into the navy i had a chance to take up mold maker
I have heard from a lot of navy guys in this background👍
When you're making your mold, it pay help to add plastic dowels in the 3d printed internals so everything lines up as you connect
Core support in the form of internal dowels or a honeycomb lattice is actually a push button option in most design software for just that reason.
Well that and physical support for prints that are finished objects as opposed to casting patterns also
20:42...aw, there are WOOFER(S)!!!
I've never seen a three part molding flask before.
You could always cast some Harley Knucklehead rocker boxes. People pay like $3K each for em sometimes.
I just gotta know what is the name of the metal wishbone dealie you use to tap the extractor dealie that screws into the plug/slug/core?
Josh that is the handle of needle nose pliers I use for rapping patterns. It does an excellent job😁
how do you mix the sand to make the mold? (Sand and ?)
Not sure I understand the question but if you are asking about the ingredients, it would be sand and Bentonite for the binder and aggregate. I have to put another things in for iron temps that serve as refractory. Not neccessary for aluminum melts
SUPER is a free video converter that can transcribe any format to almost any format. Assuming that's what you meant by technical difficulty...
Thanks, the issue I had was the customer sent a video of the machining and I couldn't view it for some reason
Question on those cores: Before cooking them in the furnace, how delicate are they to handle?
Cooking doesn't harden these, that's strictly to drive off moisture. The hardness of cores is sufficient to hold it shape ad iron floats up and around it but soft enough to easily remove.
Good work again, Sir. I wonder, how did they make their patterns in the old days for early automobile parts. Were they of wood or clay or something else? Not metal, I suppose.
Henrik, I would say wood was the primary source until the 1950's. Aluminum patterns after that. That's my guess based off what I've seen displayed in auto museums so I may be misled
I'm curious if a dip into the iron with a plug of boron like they do with aluminium would draw the dross to the top for easy removal. Never seen that done with iron before. Could save you from redoing some I would think?
Yup I'll stay in the truck all day just bring me treats.😆😆
I'm viewer number 556, I think........... :-)
👍welcome Ed👍