I worked in an aluminium foundry.We wore face and eye protection and always heated any tools that were going to be dipped into the molten metal so they were HOT before dipping.(Just put the business end in the flames for a few minutes).Even a small amount of condensation on cooler steel will generate enough steam to blow the molten metal up and far.I never saw anyone forget to do it but I heard the horror stories.
I'm sure I could do it to but I would have to wait a few years. I have the knowledge but not the machines . That was amazing. You Forged your own pulley and put it to work. I've seen the smelting of aluminum an them pouring into molds but you are the first I have seen do it all. Thank You Loader.
Need to give more time at high temp. You removed plenty of aluminium with slag. Slag itself looks like pieces of soil or rough sand floating on top of liquid alu.
This is most probably for quite a bit of weight. You made it brilliantly 👍. In my home gym I made one for my home made Smith machine. I made it from a supermarket trolley wheel. Works faaaaantastic. 🛒😂😂😂
For anyone who cant afford a lathe try your luck using a sand cast. Just get some high density styrofoam used for basement insulation. Cut out the diameter pulley you want in the styrofoam. A small chunk of ready rod placed in the center of your styrofoam with washers and nuts. Stick the ready rod in a drill chuck and then secure the drill so you can spin your styrofoam blank . As the drill spins the blank just use files and a wood chisel lightly to make the blank true and then make it in to styrofoam copy of the pulley you want. Then go watch how to sand cast. Pack your blank firm so there is no air pockets leaving one side of the blank uncovered ,then use 2 pipes or dowels ect for making pouring holes, placed on top of the blank and then cover up and pack the blank tight in sand, then pull pipes out without making sand fall in the pour holes. Pour the molten aluminum in to one of your holes and the foam pulley will be gone in a second and when you see aluminum come up the other hole in your cast your done. take the cast pulley and cut the two pieces off from pouring put back on your drill and clean up the rough spots and you have weaker pulley because it was a cast. If you make a nice cast from a balanced blank and have good pour, your cast pulley will work fine on a small engine .
Why don't you add a pre-heat hopper with secondary low level burner to facilitate faster loading? It'll get the cans closer to melting temp and allow you to dump the entire load in in one go.
Frickin' awesome! Roughly how many cans did it take to get an ingot that size? And roughly how long did the entire foundry process take? All in one day?
I have a lathe and i can drink 500 beers but can't understand the melting device.What kind is the fuel that keep the fire ?Why there are compresor and another tubrine turned by electric motor?
Dallas Woiken @ Those cans are worth about $5.00 refund... That pulley would cost around $100.00 so that is why he made the pulley from the beer cans...
I think I know where you're going with this and I'm gonna add fuel to the fire - I used plastic containers for the gasoline. :D But they are special ones not just some windshield cleaner canisters I used for the diesel fuel.
I would like to know about your forge set up, every minor detail. it appears to be the best aluminum forge on the internet. I would like with your permission to build one like it for my personal use. ty
Awesome! I watched some melting videos on youtube, and some people add borax powder to remove the gasses from the aluminum. You should try it next time.
I made this pulley straight from beer cans, thus the porosity. Making stuff from ingots leaves no porosity at all. I've used washing soda and salt for melting and casting before. This time I didn't bother. :D
The degassing results in less aluminum oxidation. Thin beer cans have a lot of surface area for the volume of aluminum. That's why melting cans produces so much slag. Melting ingots is a lot more efficient and makes degassing a lot more productive. Cans will have tons of slag either way.
What kind of fuel is that blue liquid ??? is it some sort of oil because your setup is similar to a waste oil burning setup.BTW not first but close enough 101st like.
Countries with high fuel cost burdens (take their currency to go buy US$ to go buy fuel) tax fuels differently for different users. If you're caught with eg blue heating oil (low tax) in your diesel vehicle (high tax red fuel), you get fined heavily.
No videos unfortunately. I tapered clay bricks and tied'em together with a steel strip, added clay brick bottom and filled with sand around the bricks. Heat resistand wool would be probably lighter and will warm up more easily.
I don't think there will be a next time. It seemed to turn out just fine and resulted in a functioning pulley that looks strong and runs true without any visible run-out.
Donn DIY lets see it with a belt on it, looked to me like something was wrong when the belt was fitted, old belts don’t stretch that much... either you didn’t have the right one or a ton of time wasted. Either way I don’t believe aluminum can handle the abuse your about to put on it.
Rotciv Inoccic that would be totally my opinion I've said it many a time when I watched some of these videos on UA-cam you do it for the excitement the satisfaction of knowing I can do that
I worked in an aluminium foundry.We wore face and eye protection and always heated any tools that were going to be dipped into the molten metal so they were HOT before dipping.(Just put the business end in the flames for a few minutes).Even a small amount of condensation on cooler steel will generate enough steam to blow the molten metal up and far.I never saw anyone forget to do it but I heard the horror stories.
for me, there's nothing more satisfying than watching rough cast metal being turned on a lathe
I'm sure I could do it to but I would have to wait a few years. I have the knowledge but not the machines . That was amazing. You Forged your own pulley and put it to work. I've seen the smelting of aluminum an them pouring into molds but you are the first I have seen do it all. Thank You Loader.
Thank you for watching. ;)
Nice job. Sometimes rescuing these old engines is a worthwhile project in itself and to do so using recycled material is especially satisfying.
Sir, you managed to put a smile of admiration on my face! Legendary stuff!
I'm glad you like it!
Now that was great. Really well done and brilliant use of what others throw away. Nice job. Les
Thank you very much. I'm glad you enjoyed it. Thank you for watching! ;)
I could make one. All I need is a lathe and to drink 3 cases of beer. I'll start with the beer.
Cranki You need like 1000 cans to make such pulley...
Wanna come over and drink some beer?
Cranki Absolutely.
Good choice!
Cranki nice sir
i just love it ,more unicqe projects like this pls... these cant be found anywhere on youtube,,,
I have made connecting rod, pistons, cylinder blocks and other motorcycle engine parts via this technique of old discontinued models
Genius man. pure genius. I love it.
Need to give more time at high temp. You removed plenty of aluminium with slag. Slag itself looks like pieces of soil or rough sand floating on top of liquid alu.
a thing of beauty is a joy forever, who woulda thunk a the most noble use of aluminum (as a beer can) could be added to?
This is most probably for quite a bit of weight. You made it brilliantly 👍. In my home gym I made one for my home made Smith machine. I made it from a supermarket trolley wheel. Works faaaaantastic. 🛒😂😂😂
impressive work , especially with this old bucket idea and the ending with lathe to make this nice pulley
Cheers. Bucket is a good mold becuase it's tapered and it's reusable since you can just tip the hardened aluminium out of it.
For anyone who cant afford a lathe try your luck using a sand cast.
Just get some high density styrofoam used for basement insulation. Cut out the diameter pulley you want in the styrofoam. A small chunk of ready rod placed in the center of your styrofoam with washers and nuts. Stick the ready rod in a drill chuck and then secure the drill so you can spin your styrofoam blank . As the drill spins the blank just use files and a wood chisel lightly to make the blank true and then make it in to styrofoam copy of the pulley you want.
Then go watch how to sand cast.
Pack your blank firm so there is no air pockets leaving one side of the blank uncovered ,then use 2 pipes or dowels ect for making pouring holes, placed on top of the blank and then cover up and pack the blank tight in sand, then pull pipes out without making sand fall in the pour holes. Pour the molten aluminum in to one of your holes and the foam pulley will be gone in a second and when you see aluminum come up the other hole in your cast your done.
take the cast pulley and cut the two pieces off from pouring put back on your drill and clean up the rough spots and you have weaker pulley because it was a cast. If you make a nice cast from a balanced blank and have good pour, your cast pulley will work fine on a small engine .
WOW !!! You should have a CHANNEL, ... and make some vids !!
LMFAO.
You know your stuff! Excellent work! ❤️🏆🔩⚙
Cheers!
Awesome video! It's Really nice that you used the beer cans to make something usefull!
Cheers! I thought so too. ;)
That was ridiculously awesome! Whats up with that fuel injection system for your smelter? I haven't seen that yet in your vids, looks cool.
Now, ...make an aluminium can out of a pulley !
ignorant
Хорошо получилось! Спасибо за видео.
Hi Donn DO YOU NOTICE ANY VOIDS IN THE CASTING ALUMINUM BILLIT ?
I like your vintage lathe a lot. Bought an old beast myself this week. Thanks for the nice content.
First time I see something useful from beer cans :) good job!
Beer cans are the most useful things in the world - they hold the drink of the gods - beer! :D
gee thanks now I just need a shop like yours, how can I make that? then I can make just about anything.
Buena idea de acoplar a la polea de Aluminio una brida de acero, felicitaciones y gracias por compartir.
Great video!!!
WOW 👏🏼👏🏼👏🏼.
You inspired me. I want to build a few of my parts...I might go the casting way though.
Thanks.
amazing job I noticed some of the cans had a brass colored top did this affect the aluminum?
Although the top was colored like brass it was still aluminium. The cans in these parts are made completely from aluminium.
Its great watching a pro do their magi .
Why don't you add a pre-heat hopper with secondary low level burner to facilitate faster loading? It'll get the cans closer to melting temp and allow you to dump the entire load in in one go.
Why don't you build one and make a video to show everyone how to do it.
Sir , you are a wiz kid. As the saying goes,where there is a will, there is a way.Another great video . Thanks
Thanks for watching!
Really cool,,, and ingenious, thanks for showing .
Parabéns! Um ótimo trabalho!
Frickin' awesome! Roughly how many cans did it take to get an ingot that size? And roughly how long did the entire foundry process take? All in one day?
I don't know really. A lot of cans. :D Yup, I got it done in one day.
What is the blue fuel? Great job by the way I really enjoy what you do.
And here i was, with A Le Coq can in my hand.. i guess i have to watch it all now. Which i don't mind at all, at least my A Le Coqs can be returned..
What is the fuel you're using? It looked like window cleaner !
Diesel.
Can you convert the beer belly into something useful as well?
That was some kind of cool!
I have a lathe and i can drink 500 beers but can't understand the melting device.What kind is the fuel that keep the fire ?Why there are compresor and another tubrine turned by electric motor?
Compressor helps to spray the fuel out of the nozzle and the turbine helps to regulate the incoming air and burn.
I still can't believe that there are some places that u still cant return your cans for a refund. Great project
We can return local cans, these were bought abroad. Cheers!
Donn DIY oh ok then that makes sense then.
Dallas Woiken @ Those cans are worth about $5.00 refund... That pulley would cost around $100.00 so that is why he made the pulley from the beer cans...
You are awesome! Great job, a very creative use of resources to produce something useful from waste.
Cheers!
what was the fuel you put in it? how does you fuel system work?
My only question is where did you get the gasoline for the small engine and did you transport it in a plastic or metal container?
I think I know where you're going with this and I'm gonna add fuel to the fire - I used plastic containers for the gasoline. :D But they are special ones not just some windshield cleaner canisters I used for the diesel fuel.
The camera your using is amazing.
Cheers!
I would like to know about your forge set up, every minor detail. it appears to be the best aluminum forge on the internet. I would like with your permission to build one like it for my personal use. ty
What forge? Isn't that a casting?
Great video thanks!!!👍
Thanks for watching!
so why make a pulley if the belt dont fit and you dont end up using it. the thing is just spinning there. what is its purpose?
One can't buy a belt that fits? If it's not in the video it doesn't work / doesn't exist? :D Here you go: ua-cam.com/video/J9voO5TIUNs/v-deo.html
A man can never have enough molten aluminium :)
Homemade? Maybe, but with professional equipment. Excellent concept and job in any case
Cheers.
How many can did you use?
What are you using for fuel? I do enjoy your video. Thank you.
I use diesel as fuel.
Awesome and so simple!
Cheers!
La verdad un capo ....genial tu trabajo ...
curious why the belt isn't on for the last clip.
ManMrKrazy Yes the belt has vanished.
ManMrKrazy it looks like its stretched
I couldn't find a longer belt at that moment and couldn't start the engine with this belt on. Thus no belt on in the last clip.
I thought the same 😄
Awesome.... do more..👍✌😍
How many cans? Nicely done! 👍👍👍👍😎
What make is your lathe and country of origin? Also, i really enjoy your videos, cant wait for future shop upgrade videos.
It's 1K62. Thanks for watching! The shop upgrade will take some serious time though, I will have to get some other projects out of the way first. ;)
Very cool, it's awesome you make yourself. Thank you for sharing your amazing video
Thank you, Carsten!
do you have a video of your Burner and how you make it? its awesome and want to try it.
I have a video on it here: ua-cam.com/video/i1n2j7YOanY/v-deo.html It is just a close up descriptive video not a build video, but you get my drift. :D
Вряд ли таким способом можно отлить балванку без раковин???...
ya actually turned beercans into a pulley!! Pun intended
Yes! 💪
Awesome!
Cheers!
Another great video Donn! you are an inspiration sir! keep them coming
Thanks man! Thanks for watching!
Awesome! I watched some melting videos on youtube, and some people add borax powder to remove the gasses from the aluminum. You should try it next time.
I made this pulley straight from beer cans, thus the porosity. Making stuff from ingots leaves no porosity at all. I've used washing soda and salt for melting and casting before. This time I didn't bother. :D
The degassing results in less aluminum oxidation. Thin beer cans have a lot of surface area for the volume of aluminum. That's why melting cans produces so much slag. Melting ingots is a lot more efficient and makes degassing a lot more productive. Cans will have tons of slag either way.
So how many cans did it take to make this??
I didn't count.
You are quite a master machinist great job
Thanks man!
There is only one conclusion: the world needs more beer.
That, my friend, is the right conclusion!
Good video as always 👍
Lot of work, Good.
we're those ashes in the bottom of the can you poured the molten alluminum in?
Yup, and a piece of sheet metal also.
Nicely done!
Cheers!
Amazing !!
Sometimies I get jealous watching your videos. In a good way )) Awesome, mate, very cool!
Me too.
Don't be. It's all just scrap metal. :D
Donn DIY It's not about metal, it's about Making. About process itself
Very smart!!! I love it.
Cheers.
What kind of fuel is that blue liquid ??? is it some sort of oil because your setup is similar to a waste oil burning setup.BTW not first but close enough 101st like.
EnderManiacGames industrial colored diesel fuel.
It's a mixture of agricultural diesel and cooking oil. The burner was meant for waste oil but diesel is more efficient.
Hey donn what did u use to make your dross skimmer please i want to make myself one its very effecient
Just a piece of flat scrap steel welded to a rebar. ;)
Donn DIY did i make the shape just like a stop sign for a little design
buena la idea amigo felicidades eso esta bien para un tornero que economise pero mas que todo sepa como hacerlo manualmente aluminio.
all other vids just melt cans for scrap.yours served a good purpose. nice useful pulley donn. great video. subed n liked.
Thank you very much!
Why did not you balanced it?
What is the blue liquid fuel?
Agricultural diesel fuel.
Donn DIY Thank you, its red in the states👍
Desiel
Countries with high fuel cost burdens (take their currency to go buy US$ to go buy fuel) tax fuels differently for different users.
If you're caught with eg blue heating oil (low tax) in your diesel vehicle (high tax red fuel), you get fined heavily.
Aluminium of malting point 660 degree
Awesomeness
Please, tell me you were having a beer while melting down those cans. )
No. Sorry to disappoint you. :D
How many beer cans does it take to make that pulley?
I love that engine at the end.
It took the cans shown in the video and then some. :D
Donn DIY so there was a beer run involved between shots. Lol
Good job brother thank you
How have you made the foundry? Do you have any video?
No videos unfortunately. I tapered clay bricks and tied'em together with a steel strip, added clay brick bottom and filled with sand around the bricks. Heat resistand wool would be probably lighter and will warm up more easily.
Next time allies the aluminum with housing bearings. It will make the aluminum much stronger.
I don't think there will be a next time. It seemed to turn out just fine and resulted in a functioning pulley that looks strong and runs true without any visible run-out.
cool
amigo bom dia gostaria se possivel sr faze video como fazer forno igual queria apreender obrigado super criativo.
superb,nice
Nice flywheel : )
Thanks man! :D
Donn DIY lets see it with a belt on it, looked to me like something was wrong when the belt was fitted, old belts don’t stretch that much... either you didn’t have the right one or a ton of time wasted. Either way I don’t believe aluminum can handle the abuse your about to put on it.
can u make(cast) a case like iphone 7 case or guitar/lighter or any sort of case from aluminium? would be so awesome to see.
Everything can be cast. ;)
pls pls pls... make some...
make one bro...
es muy bueno que uno mismo pueda crear nuestras propias erramientas
Do you know how much that weighed before you machined it?
and how many cans?
5,6 kg, roughly.
So, probably around 400 beer cans... It's a tough job, but *someone's* got to drink it... :)
Matt Paff
.i ahimetkaxs
Very nice 👍
What do you do with the slag???
Do you sell in at the scrapyard?
I've just collected it for now. I have to look up what I can do with it if it accumulates and gets in my way. ;)
Ok, you should ask your local scrap yards if they will take that king of material, looks to me you do this quite often.
I have to laugh at the people who don't like this video... They are people with no skills or imagination...
Rotciv Inoccic that would be totally my opinion I've said it many a time when I watched some of these videos on UA-cam you do it for the excitement the satisfaction of knowing I can do that
Awesome job!!
Thanks!
pullies cost $12 at tractor supply.