When I was at school, long before the days of 3D printing, I spent weeks making a wooden mould on a lathe for a cylindrical part I was going to cast with aluminium. The damned thing just wouldn't cast properly at all. In desperation I just stuffed a glass bottle into green sand and poured aluminium into the void left by that. After turning down on a lathe it served exactly the same purpose.
Since you have a mechanical lathe, you didn't even need to make 3d mold, just pour the molten aluminum into a cylindrical can, and then turn the billet around, much simpler and less laborious ✌️😎
great build, but question: but since you had so much good metal working macinery such as a metal cutting band saw and a metal lathe and sander, why not just pour one solid cyliinder of length 2x the length of one pully, and just use say 3" piece of abs pipe with the sand pressed around it instead of going and 3d print such a complex mold that had to get 2 part plus riser shafts and so. just a simpel cylinder in the sand with an open top, pour the metal in and let cool. then cut the long cylinder in half and machine that into the pully as shown ?
This was my thought exactly, or why even cast it at all since its just a cylinder shape, getting that kind of a small block of aluminium can't be expensive compared to the time spent creating the 3D model and mold. Why spend time sanding and filing the 3D printed mold part if its going to be machined later as well? So many things with this project that didn't quite make sense.
@@tmyalt large diameter aluminum rod isnt cheap, I actually always cast my own bar stock. I just collect aluminum scrap and casting is fun and basically free. Plus looks like he modeled in the bearing bores to save time on the lathe but couldn't get them to draw out of the sand. I assume the original intent was to use the tapers and bearing bores from the print but it just didnt work out that way in the end.
@@bottlerocket3333 a 70x100mm rod is less than 20€, comparing that to the time it took to make the 3d model, printing the model, cleaning the print, building the mold box, failing at making the mold several times, casting the metal and cleaning the part up before you actually start turning the part in the lathe is only worth it if you value your time at close to zero. I totally get that you do it because it's fun, but the question boils down to "spend 20€ or spend a full day making the bar from scratch".
@@tmyalt Like I said, he had more features intended from the casting that didn't work out that would have saved him time of they had worked out. And once you have a good pattern you can crank out a lot of parts pretty quickly. But also, I am more of a journey than the destination guy and I believe Mr.Blackbeard is too. Why waste the time restoring tools you could buy new? Why build a mag chuck when you could buy one? I don't always do things because they are the most efficient, I do them because its how I want to spend my time (and money). When you make pulleys for your home-built belt grinder you can buy bar stock. Also $20 adds up and you have to factor in shipping time too. To each his own.
All ya need is a forge, moulding sand, wood and tablessaw, 3D printer, drill press, scrap aluminum, and a metal lathe. Or you could buy a block of aluminum from a scrap yard and just use the lathe.
@@parapicktog7734 Depends on scale. For a single piece, no. Also, he gets paid for producing content. And "I bought this round stock at the store" is less engaging than casting it.
Because it's actually cheaper to cast the aluminium part. Buying such big piece of aluminium is expensive and will always waste some of it after shaping.
OK, but, I mean, surely the amount of lathe work needed means the whole 3D modelling, printing, cleaning, and casting is kinda just to generate the raw stock? It's always interesting to watch, and i may well be missing the point, but, if the video is ' how to make an aluminium wheel' does it not basically come down to 'lathe it, lad, then put t'bearing up.'
я еще вначале подумал, нахера он делает весь этот геморрой с 3d печатью, ну может токарника нет. но тут, блять, в дело вступает токарный станок... ппц, гора ненужной работы :)
mercury enema,, I was’t referring to this video solely, but yea it’s kind of pointless casting the aluminum, but none the less useful for people without access to pieces like that (the nearest metals supplier is 68km away from me,,)
@@couldbejokim4557 I also fund it very intelligent and resourceful guy, for some other people who thinks that because they did it or maybe not, is easy, is there problem, you, i and thousands of people enjoy the video and that's the point, so maybe don't give explanation to bitter people, is my opinion, have a nice day
Very nice work 💪🏼 but just a „stupid“ question... why you have moulded this piece of Al? You could have just used a piece of round material 🤪 Didn‘t you had one? Cheers ;)
Answer is likely to be "because I can" or "to get better at casting". Tubalcain did the same at some point. I agree it's a lot of work for little affect, however, same could be said for most staff home shop machinists do
Some learnings from the video. Thank you. And for those, like me, who thinks why he just didn't molded a cilinder and then putted it in the lathe, I think he wanted to avoid the lathe when he made the 3D model.
If you are going down the casting route then unless y ou want your wheels to have rough surfaces and approximate dimensions then you have to use the lathe anyway...unless you can cast metal to micrometer precision?
Good job :) for those who don't know why he did it this way. It is likely just because he had some scrap aluminum sitting around which is much cheaper than buying a piece of stock material. And he probably just wanted to practice his skills. I do the same all the time when I make things. Yes it takes more time but it is more practice on different skills, and if what he is working on is not time sensitive then it doesn't really matter. If I am making a part or fixing something for someone else I do it the most efficient way I know so I don't waste time but if it is just something for myself and it is not time sensitive I usually do it a different way.
@@joshschneider9766 Did anyone say he should do it? To me it was only suggested he should watch it. More knowledge is a good thing. And if he did decide to go down that route which is entirely up to him then he could also print another. :D
Teniendo un torno, no es necesario perder tanto tiempo en imprimir los rodillos en 3d y hacer el molde para llenarlo, simplemente hacer un cilindro con una lata y luego se tornear hasta hacerlo perfecto como uno quiera.
As soon as you made the bushing to go between the bearings, I instantly thought aluminum skateboard wheels and i am now very curious to see if you can do that
Так и не понял, накой надо было отливать такие сложные формы, если в итоге все на токарнике допилил. Можно было просто отлить в ямку 2 цилиндра и так же на токарнике потом доделать. Но все равно интересно получилось.
For ease and simplicity next time just pour the alu into a steel pipe with an inner diameter close to your intended outer diameter. Love ya buddy this vid rocked all the sam e just figure i d throw my two cents in
Who else sighed when you saw the lathe? 10 minutes of video to cast a lump of aluminium in the shape you want, 30 seconds of video to turn it into a piece of bar stock in a lathe lol
Do you have a background in foundry industries? I've been working in foundry plants for over 20 years and I'm always impressed with the castings you make.
I think you should have gone with 2RS bearings which are rubber dust SEAL instead of 2Z/ZZ which are just a metal shield and don't protect from dust. It doesn't matter now, and it might never do, but if they fail from dust ingress consider RS2 replacements.
He tends to do more metal working than wood working and what he does do is not your traditional cabinet making type of wood work. He probably feels he does not need one.
If you were going to machine them anyway, why not just pour into a soup can to make a cylinder, with no sand or 3D print needed. Also, why make orientation marks on your mold, but then not use them?
I think that is to ensure there is space around the molten metal in the main shaft for displaced air to escape. Most sand castings I have seen have air ports built in but I didn't see any here.
Извините, может быть я чего-то не понимаю, объяснит кто нибудь, для чего нужно было делать 3D модели и отливку сложную, если в итоге все доводится до ума на токарном станке?
Curious what is the cost implication of making this wheel vs buying a replacement part? It’s super awesome that you can make this. Just curious in this case if it is cost effective.
that was the craziest way possible to making that part. it would have been 100x easier just to throw a piece of round stock in the lathe and turn it down.. also that sleeve you put in at the end does absolutely nothing but make it loader. otherwise pretty good work.
I don't either. I'm guessing here but maybe the big tapered cylinder part between the 2 wheel parts act like a sump for the molten metal to fill first then flow into the wheel parts so the metal has a better chance to fully fill in the areas you really want to fill and not have to recast it again...?? Dunno, anybody can enlighten?
that came out better than I expected after you put the boxes together in a different orientation for the pour...
When I was at school, long before the days of 3D printing, I spent weeks making a wooden mould on a lathe for a cylindrical part I was going to cast with aluminium. The damned thing just wouldn't cast properly at all. In desperation I just stuffed a glass bottle into green sand and poured aluminium into the void left by that. After turning down on a lathe it served exactly the same purpose.
Clever idea!
I just like aluminium into a steel pipe whose inner diameter is close to my intended outer diameter but that's pretty smart too.
aluminium block straight to the lathe would have been easier^^ but less exciting i guess :P
Also wouldn't have been free. He must likely did it this way to use scrap aluminum instead of spending the money on a 5 inch diameter billet.
Great work! Really cool that you can make this usable parts yourself :) Love that
Complimenti, si vede che c'è uno studio dietro lo stampo, non è da tutti fare un canale di colata con tanto di bacino di colata e una materozza
Using Tongue and Groove hardwood flooring for making casting boxes... absolutely brilliant! Keep up the great work!
Since you have a mechanical lathe, you didn't even need to make 3d mold, just pour the molten aluminum into a cylindrical can, and then turn the billet around, much simpler and less laborious ✌️😎
Lol I use a steel pipe but yeah gmta
It was more to showcase his skills improving with casting and the use of CAD/3D printers for a blank.
Can’t wait to see the finished product!
Watch the whole video and you’ll see it!
great build, but question:
but since you had so much good metal working macinery such as a metal cutting band saw and a metal lathe and sander, why not just pour one solid cyliinder of length 2x the length of one pully, and just use say 3" piece of abs pipe with the sand pressed around it instead of going and 3d print such a complex mold that had to get 2 part plus riser shafts and so. just a simpel cylinder in the sand with an open top, pour the metal in and let cool. then cut the long cylinder in half and machine that into the pully as shown ?
True
This was my thought exactly, or why even cast it at all since its just a cylinder shape, getting that kind of a small block of aluminium can't be expensive compared to the time spent creating the 3D model and mold. Why spend time sanding and filing the 3D printed mold part if its going to be machined later as well? So many things with this project that didn't quite make sense.
@@tmyalt large diameter aluminum rod isnt cheap, I actually always cast my own bar stock. I just collect aluminum scrap and casting is fun and basically free. Plus looks like he modeled in the bearing bores to save time on the lathe but couldn't get them to draw out of the sand. I assume the original intent was to use the tapers and bearing bores from the print but it just didnt work out that way in the end.
@@bottlerocket3333 a 70x100mm rod is less than 20€, comparing that to the time it took to make the 3d model, printing the model, cleaning the print, building the mold box, failing at making the mold several times, casting the metal and cleaning the part up before you actually start turning the part in the lathe is only worth it if you value your time at close to zero. I totally get that you do it because it's fun, but the question boils down to "spend 20€ or spend a full day making the bar from scratch".
@@tmyalt Like I said, he had more features intended from the casting that didn't work out that would have saved him time of they had worked out. And once you have a good pattern you can crank out a lot of parts pretty quickly. But also, I am more of a journey than the destination guy and I believe Mr.Blackbeard is too. Why waste the time restoring tools you could buy new? Why build a mag chuck when you could buy one? I don't always do things because they are the most efficient, I do them because its how I want to spend my time (and money). When you make pulleys for your home-built belt grinder you can buy bar stock. Also $20 adds up and you have to factor in shipping time too. To each his own.
I don't want to be cheeky but wouldn't it be easier to find a round aluminium rod?
Cost. Casting your own Aluminium bar or cylinder stock is cheaper than buying it.
@@markfryer9880 he took took to much effort to make a mould.
He could just make cylindrical hole in sand with cardboard tube.
All ya need is a forge, moulding sand, wood and tablessaw, 3D printer, drill press, scrap aluminum, and a metal lathe.
Or you could buy a block of aluminum from a scrap yard and just use the lathe.
@@markfryer9880 no it isn't.
@@parapicktog7734 Depends on scale. For a single piece, no.
Also, he gets paid for producing content. And "I bought this round stock at the store" is less engaging than casting it.
I salute you man for showing us the mistakes. Thanks for being real!
Why not make the whole thing out of a cylinder of metal and lathe that instead of the additional process of moulding?
Because it's actually cheaper to cast the aluminium part. Buying such big piece of aluminium is expensive and will always waste some of it after shaping.
Where's the fun in that???
Stavros
a 30 minute lathe project turned into god knows how long of a casting project. nice.
Your going supersonic with that saw
Me encantó tu video amigo. Saludos de “AZTECA KNIVES” desde Ecatepec, México 🇲🇽
OK, but, I mean, surely the amount of lathe work needed means the whole 3D modelling, printing, cleaning, and casting is kinda just to generate the raw stock?
It's always interesting to watch, and i may well be missing the point, but, if the video is ' how to make an aluminium wheel' does it not basically come down to 'lathe it, lad, then put t'bearing up.'
When he was hammering the nails in and he fast forwarded it made in look like it pushing the in without touching them
This was hilarious yet also phenomenal workmanship. Nice job man
Можно было просто залить алюминий в банку консервную, все равно на токарном обрабатывал заготовку.
Вот вот, действительно. Столько ненужных манипуляций.
@@sergey.stafeev Особенно стачивание облоя напильником.
не ищет легких путей гемор наверное любит
я еще вначале подумал, нахера он делает весь этот геморрой с 3d печатью, ну может токарника нет. но тут, блять, в дело вступает токарный станок... ппц, гора ненужной работы :)
Buona sera! Siempre Milton piaccere veddere tu lavuoro !💪
This is why this is my favorite channel, this man is just so ducking ingenious,,
mercury enema,, I was’t referring to this video solely, but yea it’s kind of pointless casting the aluminum, but none the less useful for people without access to pieces like that (the nearest metals supplier is 68km away from me,,)
@@couldbejokim4557 I also fund it very intelligent and resourceful guy, for some other people who thinks that because they did it or maybe not, is easy, is there problem, you, i and thousands of people enjoy the video and that's the point, so maybe don't give explanation to bitter people, is my opinion, have a nice day
Iroh27 thanks mate!! Have a great day!!
Good stuff, well done. Loved to have seen your foundry.
Very good content and work but you will more then made another type of making this easily whatever love from pakistan 🇵🇰🇵🇰
Thanks for watching the video
What a great skill. Cheers man
Very nice work 💪🏼 but just a „stupid“ question... why you have moulded this piece of Al? You could have just used a piece of round material 🤪 Didn‘t you had one? Cheers ;)
This is not a stupid question
Exact same question.
Because this way he can recycle leftover pieces or cans maybe even the chips etc😄
@@jelletool6504 its a bad idea ..he can cast direccasta cylinder without wasting PLA in 3d printing
Answer is likely to be "because I can" or "to get better at casting". Tubalcain did the same at some point. I agree it's a lot of work for little affect, however, same could be said for most staff home shop machinists do
Nice! :D I dreamed some years ago about doing the same thing, but now i know it's a long way until i could do this.
Some learnings from the video. Thank you.
And for those, like me, who thinks why he just didn't molded a cilinder and then putted it in the lathe, I think he wanted to avoid the lathe when he made the 3D model.
If you are going down the casting route then unless y ou want your wheels to have rough surfaces and approximate dimensions then you have to use the lathe anyway...unless you can cast metal to micrometer precision?
Awesome !!!!!!!!!!!! Very impressive too !!!!!!!!!!!!!!!
Great full ideas
After putting the sand box together it was not advisable to use impact screw driver. It could break the sand.
Good job :) for those who don't know why he did it this way. It is likely just because he had some scrap aluminum sitting around which is much cheaper than buying a piece of stock material. And he probably just wanted to practice his skills. I do the same all the time when I make things. Yes it takes more time but it is more practice on different skills, and if what he is working on is not time sensitive then it doesn't really matter. If I am making a part or fixing something for someone else I do it the most efficient way I know so I don't waste time but if it is just something for myself and it is not time sensitive I usually do it a different way.
Job well done, gotta make a couple for myself.
You sir, are a damn genius!
your videos go crazy man good work
You should look up myfordboy's video on burning out PLA prior to casting.
Definitely worth checking out, he's the don of casting. :D
Except now he has a match plate that will never rot unlike wood onrs. Why would he melt that out like lost wax?
@@joshschneider9766 Did anyone say he should do it?
To me it was only suggested he should watch it.
More knowledge is a good thing.
And if he did decide to go down that route which is entirely up to him then he could also print another. :D
Ты - Магистр☝️👍👍👍
Teniendo un torno, no es necesario perder tanto tiempo en imprimir los rodillos en 3d y hacer el molde para llenarlo, simplemente hacer un cilindro con una lata y luego se tornear hasta hacerlo perfecto como uno quiera.
Why did you decid to flatten the crown from the mold and recut with compound rather than clean with compound directly?
Good work man.
It seems like you make new casting frames all the time!
Cool result
Thank you, the video was very helpful.
As soon as you made the bushing to go between the bearings, I instantly thought aluminum skateboard wheels and i am now very curious to see if you can do that
Nice work
Grande! La struttura l’hai disegnata e realizzata tu? Si può avere qualche disegno, per favore? Grazie mille 💪🏻👍🏻
Так и не понял, накой надо было отливать такие сложные формы, если в итоге все на токарнике допилил. Можно было просто отлить в ямку 2 цилиндра и так же на токарнике потом доделать. Но все равно интересно получилось.
Excelente trabajo, felicitaciones.
Congratulation 👍 brother.
Hello, I really like your videos. I notice you updated your table saw fence, can you show us now, because I have the same problem there :)
Nice!!
Enjoyed your video so gave it a Thumbs Up
Nice carpentry work. When did you get the printer? That has to make your casts a lot cleaner.
What was the purpose of the coloured spray paint dots. They didn't line up when the casting took place.
А для чего были нужны эти танцы с 3 д принтером и литьём сложной формы, если всё перетачивалось на токарном
Wow mantap juga keren om hasil nya bagus banget
For ease and simplicity next time just pour the alu into a steel pipe with an inner diameter close to your intended outer diameter. Love ya buddy this vid rocked all the sam e just figure i d throw my two cents in
..GOOD ONE, KEEP SAFE...
Who else sighed when you saw the lathe? 10 minutes of video to cast a lump of aluminium in the shape you want, 30 seconds of video to turn it into a piece of bar stock in a lathe lol
Good job! Thank's to show
Do you have a background in foundry industries? I've been working in foundry plants for over 20 years and I'm always impressed with the castings you make.
I think you should have gone with 2RS bearings which are rubber dust SEAL instead of 2Z/ZZ which are just a metal shield and don't protect from dust. It doesn't matter now, and it might never do, but if they fail from dust ingress consider RS2 replacements.
If you keep replaying from 1:18 to 1:20 it sounds like a hip hop beat lol... ive been doing it for 10 minutes now lol
thanks. now my afternoon is wasted. dam u
@@thesage1096 hahahha... sorry :(
Never seen black casting sand before.
very good friend, let's do well together, see you guys again
@ 7:00 , I feel your frustration brother.
your green sand looks like coffee grounds. i wanna make an espresso
I’m curious why you put a floating collar inside of the roller?
To prevent side loading the bearing. Now when he tightens down the nut all the clamping force is on the inner race of the bearing.
So I have this right...table saw, 2x72 sander, drill press, etc, but no cross-cut saw?
He tends to do more metal working than wood working and what he does do is not your traditional cabinet making type of wood work. He probably feels he does not need one.
You should try acetone vapor for smoothing out your prints
If you were going to machine them anyway, why not just pour into a soup can to make a cylinder, with no sand or 3D print needed. Also, why make orientation marks on your mold, but then not use them?
Because you don’t use t&g for the casting flasks
Por lo visto el barba sabe mucho
Where can I find these 13:20 manual hand presses, what is that brand?
I think they are called arbor presses. Machinery places could sell them.
What is the reason making that small cavity beside the hole? Smoother pour? Overfill catch?
I think that is to ensure there is space around the molten metal in the main shaft for displaced air to escape. Most sand castings I have seen have air ports built in but I didn't see any here.
Lovely sir
awesome gj bro
Ukinnam bulataw tiplaken ka ket
if you have a lathe
¿Why do you melt it?
Nice job!
Casting your own is good for keeping that skill set sharp.
Hello! Is there a way to make the file of the parts available for 3d printing? Please!
What kind of material is used to make the mold?
6:57 *ECCO COS'ERA QUELLA BESTEMMIA CHE HO SENTITO DA CASA MIA...*
Извините, может быть я чего-то не понимаю, объяснит кто нибудь, для чего нужно было делать 3D модели и отливку сложную, если в итоге все доводится до ума на токарном станке?
не ищет легких путей гемор наверное любит
why doesn't this cast need two holes?
hey can u make a wooden bird/pigeon cage a small one
رائع 👍🇩🇿
Can someone explain why he had to cast the piece from scratch rather than just form it from a aluminum square?
Because he had a bunch of scrap aluminium lying around taking up space?
I see that you wasted the 3d printer filament..you can get a normal bar or just cast an aluminium cylinder ther machine it
Curious what is the cost implication of making this wheel vs buying a replacement part? It’s super awesome that you can make this. Just curious in this case if it is cost effective.
Not sure for him but for me casting into a stereotype is wwwwaaaayyyyy cheaper.
Steel tube not stereotype
What does melted metal smell like
Believe me!!...............it smells exactly like burning flesh when I do it!!!
Stavros of Etna
that was the craziest way possible to making that part.
it would have been 100x easier just to throw a piece of round stock in the lathe and turn it down..
also that sleeve you put in at the end does absolutely nothing but make it loader.
otherwise pretty good work.
4:45 someone has been watching From Dusk till Dawn, eh?!
Why did you make that odd shaped plastic shape when you just ended up turning them into a normal cylinder lol I don’t understand
I don't either. I'm guessing here but maybe the big tapered cylinder part between the 2 wheel parts act like a sump for the molten metal to fill first then flow into the wheel parts so the metal has a better chance to fully fill in the areas you really want to fill and not have to recast it again...?? Dunno, anybody can enlighten?
Buen video
👍
Nice
Ок👍👍👍
Cool!
👍😉
amazing
cool