thank you for sharing your incredible workmanship , truly impressive . I've tried to find info on lost foam casting ,but; didn't truly understand how it was done ?! Looks like the capabilities to do really good work using this method is possible .
You might want to join www.TheHomeFoundry.og casting forum. There is a Lost Foam Casting sub forum there with lots of practical info in addition to other casting processes, all geared toward the home gamer. Best, Kelly
Hi Kelly, you always amaze me with your process, I still cannot believe how you get the manifold to match the taper, bolt holes and depth to the heads of the engine! thank you for sharing, Rich
You have all tools and toys but most important all 3d concepts in your mind and metallurgic process for developing all this projects nice God bless you and yours.
@kellycoffield533 I remember in the 70's all the coordinates (xyz) had to be entered manually without graphics on screen you only had the blueprints, today there are many very good apps and software
I had 2 1970 Boss 302 mustangs in the 70's. I remember seeing the Ford made intake system like this it was called "The Cross Boss" . pretty valuable today.
Dude. YOU sir, are a national treasure. Don't know how you do what you do .. nor your original inclination. BUT I HAVE ALWAYS enjoyed YOU SHARING this process. Friggin' AMAZING. ❤
I don't recall if you've talked about this in past videos but I've never seen you use flux or degasser prior to pouring. If you have forgive my memory Kelly. Another great casting and video.👍
Much of the need for fluxing and degassing *can* be avoided with use of non-combustion melting. Porous castings - lots of little pinholes - make for obnoxious machining. I’ve done a few. This fellow’s way beyond anything I’ve done.
I don't degas because: I use virgin ingot for these projects in a resistive electric furnace which has a very favorable atmosphere for aluminum casting because it isn't moving loads of air/water/fuel through the furnace which can all contribute to H2 porosity. In fact, my furnace is sealed up well and I believe is actually depleted O2 atmosphere.....until I open it of course. Back whenn I used a lot of scrap, I used to degas. If you go way back in my videos (see links below), when I used to cast with scrap and remelt, I did degas. If I use such metal these days it's usually on ornamental stuff, but even so, I don't seem to have metal quality problems and I attribute that largely to furnace atmosphere. Best, Kelly Videos: ua-cam.com/video/Vr4kh9mzYJU/v-deo.htmlsi=dpgBom44x1XxLzqs ua-cam.com/video/WSoKCyidQXY/v-deo.htmlsi=r8u3WZJ6XDqu3z1u Build Thread: forums.thehomefoundry.org/index.php?threads/degassing-lance.204/
Super neat! I had no idea one could make something like this "at home'. Granted you have some nice equipment for the process, but that's clearly your driveway and not an industrial park. Whole process neat to watch and I don't even care about cars. I'm looking forward to watching the rest of your videos later.
Yes, in addition to improved surface finish, it also controls the rate at which the evaporated foam escapes to the mold, thus also controls the rate at which the molten metal front advances. Best, Kelly
A shop I worked had a Foundry made castings for injection molds/ when molds were poured they mounted a vibration box to get air out and less porosity in the castings
Well, I don't want to jinx myself because have been enjoying quite a run of successes. The last fail resulting in an unusable casting was Part 2 of my Boss 302 IR manifold and was due to contaminated sand and insufficiently packed mold, but that was 3 yrs and many projects ago. Rarely, I do find a small, imbedded flaw when machining, usually from trash that broke loose during the pour. I think I commented on that in my Mercruiser 470 Manifold video. It was small, like the size of a pencil eraser. This wouldn't have affected function but 356 is very weldable, I have a die grinder and TIG, and know how to use them. 15 minutes for something like that. One big difference between me an production foundries......I need to get it right the first time and don't have the benefit of doing process development work for each casting. Best, Kelly
Yes I do. I cast with 356 alloy and use aT5 schedule which is 445F for 8hrs with no controlled cooling required. T5 only requires Precipitation phase above, whereas T6 requires solution phase at 1000F. It's difficult to control temps in such a furnace and it risks localized damage to the casting, and also requires a quench which can also distort castings. T5 improves machinability and achieves 80% of the mechanical properties as T6 with no risk to the casting. I see peopleT5 small parts in toaster ovens. Best, Kelly
I'm new to the channel and can't wait to see more of your other earlier episodes. I was wondering if you would mind if I pass on your info to a small number engine builder? He sometimes gets interest on his channel to get together with a few other builders to order multiples of an item so everyone can continue with their builds? I'm looking forward to seeing your next project. I hope you stay safe, stay healthy and are as happy as you can be in everything you do in life. 🤘😁👍 Hello Hello From Canada!!!
Yes but not too seriously. Jay Brown's adapter is out there for use with 351c TRs which are cheap and plentiful. My casting flask is marginally/if capable of accommodating the extra width of an FE intake, and it's a lot of work to reverse engineer all the machine features. That's why I used Jays adapter for my FE project, which also did the groundwork for 351c. Plus, the adapter itself has many advantages. Best, Kelly
Beautiful work as always Kelly. For gluing the top and bottom spider halves, the glued lateral edges of the runners look really good, but would keying features help on location, or only lead to more misalignement sanding because of foam machining tolerance stackup already compensated for by hand? Thanks.
Keying might help but foam is pretty fragile for small features like that and I've concluded it just isn't worth the added complexity. The high tack PVA glue allows working time and is self-fixturing to a degree for adjusting fitment of the pieces. Binding the joints with tape stitches and weighting works really well to compress the joint until cured and is simple in practice. Best, Kelly
Always love it when you come out with a new video. I've poked Jack of Number 27 (YT) to look at having something made for his De Tomaso Pantera if he can afford it.
I like both processes but I think you will find as part size increases, the mold material and overall labor costs for a casting become much less for lost foam. Fine details and surface finish will be dictated by that possible with the foam pattern, which may be somewhat lesser than that with wax or resin printing. Best, Kelly
Did your shrinkage rate calculations work out good? How close can it get, once you mount it into a mill, and can measure accurately ? Very nice work. Also, did you do a T3 post heat treat ? What aluminum did you use 6061?
Shrinkage of 1.3% and it is always bang on. A356 alloy, T5. Getting the fixture accurately located in the mill and the casting on the fixture is a bigger challenge than shrinkage accuracy. See responses below for further heat treat explanation. Best, Kelly
It's Extruded Polystyrene foam insulation board available at the big box stores. There is a video dedicated to pattern materials available on my channel. Best, Kelly
@ I’ve used the heavy pattern making foam that’s also pink, but it’s very expensive. Good to know such good results come from relatively cheap material.
Another beautiful casting & project Sir. I am curious on your heat-treating schedule. Are you sending the part out or aging in an oven in your shop? Thanks & looking fwd. to seeing your next project.
I cast with 356 alloy and use aT5 schedule which is 445F for 8 hrs with no controlled cooling required. T5 only requires Precipitation phase above, whereas T6 requires solution phase at 1000F. It's difficult to control temps in such a furnace and it risks localized damage to the casting, and also requires a quench which can also distort castings. T5 improves machinability and achieves 80% of the mechanical properties as T6 with no risk to the casting. I see peopleT5 small parts in toaster ovens. Best, Kelly
Been approached on that one several times. 48IDAs are bit smallish for the displacements most are building today, and 58IDAs rarer than Inlines. Would rather do an Inline Carb version. Best, Kelly
Pretty easy to quote fuel materials plus labour cost it's a two thousand dollar manifold roughly to buy oem 3 hundred thousand dollar shelb6 mustang this guy has some passion
I'm pretty sure they call that part the Cross over that connects both heads to the water outlet ....And what type of Carburetor flange are you going to mount to that rather narrow intake manifold plenum ????????????????????
Crossover, water neck, it's just jargon. The intake is 2-piece so it can accommodate any 1 of the 4 different Inline carb adapters discussed in the video (flat and angled carb pad in each of the two Inline Carb sizes), and also to make access to the plenum and runner entry windows easy if one wanted to port or polish. Best, Kelly
I have an both an 8kw and 22kw resistive electric furnace. Both melt aluminum to pour temp at about 4-5 cents/lb of aluminum from a cold start. On this pour I melted just short of 40lbs. It took about 55 minutes at full power. I pay ~10c/kw-hr, so this 40lb melt cost me about $2. I don't have to store fuel nor can I run out, and start up is a flick of a switch. Best, Kelly
www.inlinecarb.com for the Carbs. It's in drastic need of updating which I will do in the near future. I'm an admin at www.TheHomeFoundary.org for casting related topics. As far as projects, I cast a lot of things for myself but otherwise really only inline carb manifolds for Ford engines.....but ya never know. Best, Kelly
Next time instead of using you adjustment screw go out and get dental plaster and mix it up and stick it under your part all over the under side then machine it. the DP is so must stronger you wont have to worry about it moving around when you are machining it. you can use plaster Paris but it takes a long time to cure. Mud it in.
These are some of my favorite videos on UA-cam.
I wish you were my neighbor. I wouldn't leave you alone. Coolest channel on you tube for me, personally.
what stunning work.
years and years of knowledge to pull that off
That is a thing of beauty Kelly. Thanks for taking us along for the ride.
thank you for sharing your incredible workmanship , truly impressive . I've tried to find info on lost foam casting ,but; didn't truly understand how it was done ?! Looks like the capabilities to do really good work using this method is possible .
You might want to join www.TheHomeFoundry.og casting forum. There is a Lost Foam Casting sub forum there with lots of practical info in addition to other casting processes, all geared toward the home gamer. Best, Kelly
I always wanted to see one for the 429 with dual inline 4's. Very nicely done sir.
I'm working on that one. It's going to be great! Best, Kelly
Hi Kelly, you always amaze me with your process, I still cannot believe how you get the manifold to match the taper, bolt holes and depth to the heads of the engine!
thank you for sharing, Rich
That is definitely the most impressive casting setup i've ever seen. Wow.
You have all tools and toys but most important all 3d concepts in your mind and metallurgic process for developing all this projects nice God bless you and yours.
The world changed when I added CAD/CAM to the tool set. Best, Kelly
@kellycoffield533 I remember in the 70's all the coordinates (xyz) had to be entered manually without graphics on screen you only had the blueprints, today there are many very good apps and software
Talented man what a man this is what we are losing in America men like this
Wow man like wow man that is impressive you are smart really really smart I wish i had half your skill and knowledge. 👍🇭🇲
Amazing work as always, thanks for sharing!
I had 2 1970 Boss 302 mustangs in the 70's. I remember seeing the Ford made intake system
like this it was called "The Cross Boss" . pretty valuable today.
I have CrossBoss intakes and Inline Carbs available for sale. www.inlinecarb.com Best, Kelly
Very impressive work! Thanks for the video! 😎👍
Great work!
Dude. YOU sir, are a national treasure. Don't know how you do what you do .. nor your original inclination. BUT I HAVE ALWAYS enjoyed YOU SHARING this process. Friggin' AMAZING. ❤
Always great to see you in my feed. Another masterpiece and great inspiration. Thank you!
It'a a shame I have no need for one of your systems. They are fantastic!
Easy to remedy......Just go buy a late 60s Ford muscle car.😁
Always Awesome, makes me wish I still had my Boss 302!
Amazing work as always Kelly
Congratulations,nice piece of art .Thank you for shearing your knowledge!
A masterpiece, wonderful piece!
I don't recall if you've talked about this in past videos but I've never seen you use flux or degasser prior to pouring. If you have forgive my memory Kelly. Another great casting and video.👍
Much of the need for fluxing and degassing *can* be avoided with use of non-combustion melting.
Porous castings - lots of little pinholes - make for obnoxious machining. I’ve done a few.
This fellow’s way beyond anything I’ve done.
I don't degas because: I use virgin ingot for these projects in a resistive electric furnace which has a very favorable atmosphere for aluminum casting because it isn't moving loads of air/water/fuel through the furnace which can all contribute to H2 porosity. In fact, my furnace is sealed up well and I believe is actually depleted O2 atmosphere.....until I open it of course. Back whenn I used a lot of scrap, I used to degas. If you go way back in my videos (see links below), when I used to cast with scrap and remelt, I did degas. If I use such metal these days it's usually on ornamental stuff, but even so, I don't seem to have metal quality problems and I attribute that largely to furnace atmosphere. Best, Kelly
Videos:
ua-cam.com/video/Vr4kh9mzYJU/v-deo.htmlsi=dpgBom44x1XxLzqs
ua-cam.com/video/WSoKCyidQXY/v-deo.htmlsi=r8u3WZJ6XDqu3z1u
Build Thread:
forums.thehomefoundry.org/index.php?threads/degassing-lance.204/
@@kellycoffield533 Thanks Kelly.
Awesome job man beautiful part
Beautiful work as always Kelly!
I am always amazed by your projects.
A work of art. Well done
TOTALY AWESOME!
Fascinating stuff! Thanks for walking us through what goes into casting in aluminum!
Thanks for sharing 👍 and Merry Christmas to you and your family 😅
Fantastic video. Thanks.
Super neat! I had no idea one could make something like this "at home'. Granted you have some nice equipment for the process, but that's clearly your driveway and not an industrial park. Whole process neat to watch and I don't even care about cars. I'm looking forward to watching the rest of your videos later.
That Autolite inline is worth a nice chunk of change.
That turned out great.
most inpressive sir,,,,,thanks
love the portable foundry
Wow marvelous work!
astounding!! great work.
I'm in awe! Very impressive. Thank you.
Good stuff!
Beautiful work!
You are a master at your craft
Awesome job 👍
Very cool!
awesome!
Nice pour. Is the dip coating only for the increased surface quality or does it effect the casting process somehow?
Yes, in addition to improved surface finish, it also controls the rate at which the evaporated foam escapes to the mold, thus also controls the rate at which the molten metal front advances. Best, Kelly
A shop I worked had a Foundry made castings for injection molds/ when molds were poured they mounted a vibration box to get air out and less porosity in the castings
I hope someday a company reproduces the autolite inline. The linear carb configuration has great dyno evidence to support it.
This is cool!
Excellent video! I’m curious about how often, despite all your efforts to avoid problems, that you have a casting failure?
Well, I don't want to jinx myself because have been enjoying quite a run of successes. The last fail resulting in an unusable casting was Part 2 of my Boss 302 IR manifold and was due to contaminated sand and insufficiently packed mold, but that was 3 yrs and many projects ago. Rarely, I do find a small, imbedded flaw when machining, usually from trash that broke loose during the pour. I think I commented on that in my Mercruiser 470 Manifold video. It was small, like the size of a pencil eraser. This wouldn't have affected function but 356 is very weldable, I have a die grinder and TIG, and know how to use them. 15 minutes for something like that. One big difference between me an production foundries......I need to get it right the first time and don't have the benefit of doing process development work for each casting. Best, Kelly
Would you cast some AlumBronze parts for an Engine Dyno ?
Is someone currently making these carburetors? Surely there can't be that many still in circulation. Awesome job as usual.
They haven't been made since 1972. They're collector's items but I have enough of them to support my customers. Best, Kelly
Do you do your heat treating with your furnace too?
Yes I do. I cast with 356 alloy and use aT5 schedule which is 445F for 8hrs with no controlled cooling required. T5 only requires Precipitation phase above, whereas T6 requires solution phase at 1000F. It's difficult to control temps in such a furnace and it risks localized damage to the casting, and also requires a quench which can also distort castings. T5 improves machinability and achieves 80% of the mechanical properties as T6 with no risk to the casting. I see peopleT5 small parts in toaster ovens. Best, Kelly
I'm new to the channel and can't wait to see more of your other earlier episodes. I was wondering if you would mind if I pass on your info to a small number engine builder? He sometimes gets interest on his channel to get together with a few other builders to order multiples of an item so everyone can continue with their builds? I'm looking forward to seeing your next project. I hope you stay safe, stay healthy and are as happy as you can be in everything you do in life.
🤘😁👍 Hello Hello From Canada!!!
Sure, feel free to pass it along. That's why I make them. Best, Kelly
You ever consider making a tunnel ram for FE?
Yes but not too seriously. Jay Brown's adapter is out there for use with 351c TRs which are cheap and plentiful. My casting flask is marginally/if capable of accommodating the extra width of an FE intake, and it's a lot of work to reverse engineer all the machine features. That's why I used Jays adapter for my FE project, which also did the groundwork for 351c. Plus, the adapter itself has many advantages. Best, Kelly
@@kellycoffield533 Thank you
I got to ask. Just how much does this cost to create?
Beautiful work as always Kelly. For gluing the top and bottom spider halves, the glued lateral edges of the runners look really good, but would keying features help on location, or only lead to more misalignement sanding because of foam machining tolerance stackup already compensated for by hand? Thanks.
Keying might help but foam is pretty fragile for small features like that and I've concluded it just isn't worth the added complexity. The high tack PVA glue allows working time and is self-fixturing to a degree for adjusting fitment of the pieces. Binding the joints with tape stitches and weighting works really well to compress the joint until cured and is simple in practice. Best, Kelly
Always love it when you come out with a new video. I've poked Jack of Number 27 (YT) to look at having something made for his De Tomaso Pantera if he can afford it.
Send him this one ua-cam.com/video/mqriVTlzGic/v-deo.htmlsi=hciw4rrF634j1l2Y
I work in investment casting, really interested in your lost foam process!
I like both processes but I think you will find as part size increases, the mold material and overall labor costs for a casting become much less for lost foam. Fine details and surface finish will be dictated by that possible with the foam pattern, which may be somewhat lesser than that with wax or resin printing. Best, Kelly
Great video showing the process of lost foam casting. How long does it take to machine the foam core?
About 2 1/2 hours for all of the pieces in the pattern, 2hrs of which are the two pieces in the center runner and plenum assembly. Best, Kelly
Awesome. The 335 & 385 series, and Windsor blocks all are pretty similar looking, Windsor heads are different tho.
For sure and Boss 429 heads a very different from all of them. Best, Kelly
That would fit my '86 460, right? Oops, I didn't catch the Boss 429 part.
All you need to do is put a set of Kaase B9 heads on it. 😁 I could make a CJ/SCJ or even A460 version if properly motivated. Best, Kelly
Did your shrinkage rate calculations work out good? How close can it get, once you mount it into a mill, and can measure accurately ? Very nice work.
Also, did you do a T3 post heat treat ? What aluminum did you use 6061?
Shrinkage of 1.3% and it is always bang on. A356 alloy, T5. Getting the fixture accurately located in the mill and the casting on the fixture is a bigger challenge than shrinkage accuracy. See responses below for further heat treat explanation. Best, Kelly
Very impressive. Are you using prototyping foam or just regular sheet stuff you get from a hardware store?
It's Extruded Polystyrene foam insulation board available at the big box stores. There is a video dedicated to pattern materials available on my channel. Best, Kelly
@ I’ve used the heavy pattern making foam that’s also pink, but it’s very expensive. Good to know such good results come from relatively cheap material.
Another beautiful casting & project Sir. I am curious on your heat-treating schedule. Are you sending the part out or aging in an oven in your shop? Thanks & looking fwd. to seeing your next project.
I cast with 356 alloy and use aT5 schedule which is 445F for 8 hrs with no controlled cooling required. T5 only requires Precipitation phase above, whereas T6 requires solution phase at 1000F. It's difficult to control temps in such a furnace and it risks localized damage to the casting, and also requires a quench which can also distort castings. T5 improves machinability and achieves 80% of the mechanical properties as T6 with no risk to the casting. I see peopleT5 small parts in toaster ovens. Best, Kelly
Awesome work as always. Or do you have a magic wand hidden off camera? 😁
Just artwork...
Ever consider doing the 427 sohc Weber intake?
Been approached on that one several times. 48IDAs are bit smallish for the displacements most are building today, and 58IDAs rarer than Inlines. Would rather do an Inline Carb version. Best, Kelly
What do you charge for something like that ? Or I should say how ?
Pretty easy to quote fuel materials plus labour cost it's a two thousand dollar manifold roughly to buy oem 3 hundred thousand dollar shelb6 mustang this guy has some passion
@@Bigwillydingdong I'd take an old survivor Ford and put my money into a part like this to make it unique rather than hundreds of hours of body work.
Amazing! Did you need to make the foam pieces 5% larger to allow for size reduction after cooling?
The shrink factor is 1.3%. Best, Kelly
Just for fun, have you considered misaligning the upper tubes? This, to induce turbulence and enhance combustion.
I'm pretty sure they call that part the Cross over that connects both heads to the water outlet ....And what type of Carburetor flange are you going to mount to that rather narrow intake manifold plenum ????????????????????
Crossover, water neck, it's just jargon. The intake is 2-piece so it can accommodate any 1 of the 4 different Inline carb adapters discussed in the video (flat and angled carb pad in each of the two Inline Carb sizes), and also to make access to the plenum and runner entry windows easy if one wanted to port or polish. Best, Kelly
How much electricity does your kilm use in dollars when you do a pour?
I have an both an 8kw and 22kw resistive electric furnace. Both melt aluminum to pour temp at about 4-5 cents/lb of aluminum from a cold start. On this pour I melted just short of 40lbs. It took about 55 minutes at full power. I pay ~10c/kw-hr, so this 40lb melt cost me about $2. I don't have to store fuel nor can I run out, and start up is a flick of a switch. Best, Kelly
Thanks for your response.@@kellycoffield533
If you see one Boss 429 lost foam cast intake manifold for an Autolite inline carburetor system, you've seen them all.
Do you have a website and or do custom projects?
www.inlinecarb.com for the Carbs. It's in drastic need of updating which I will do in the near future. I'm an admin at www.TheHomeFoundary.org for casting related topics. As far as projects, I cast a lot of things for myself but otherwise really only inline carb manifolds for Ford engines.....but ya never know. Best, Kelly
Хера себе ты крут мужик
Next time instead of using you adjustment screw go out and get dental plaster and mix it up
and stick it under your part all over the under side then machine it. the DP is so must stronger you wont have to worry about it moving around when you are machining it. you can use
plaster Paris but it takes a long time to cure. Mud it in.
Love your work! You are such an inspiration for me!