STEP PULLEY
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- Опубліковано 12 жов 2020
- This video is about molding and casting a step pulley from a 3D printed pattern with some bonus material.
windyhillfoundry.com/
#windyhillfoundry #castiron #madeinmississippi #steppulley #skillet - Наука та технологія
Happy Anniversary to Chad and Stephanie. It's so cool to partner with them in making a lasting memento. :)
Very cool- thanks
Frank
+1 For neighbors & friends you didn't know you had.
Nice job. The die casting job sounds like an opportunity and a risk. When I had my business we got involved with several national companies. They funneled lots work my way. They were very demanding on deliver time. Most delayed payment for 60 to 90 days after delivery. Twice it required required considerable up front investments in new equipment and training. The fact is either could have decided to go someplace else in an instant if they found a cheaper supplier or decided on a different product line. I had lost one big account when the manager was replaced and came with a supplier from his last job. Another account was lost when they decided to buy a bigger injection molding machine and move my product to that operation. Try to diversify your customer base! I was in manufacturing most of my life. From a one man shop to 24 employees. A wild ride! Good luck.
This happens more than people realize. That's the reason I mentioned not forgetting the smaller customer. I was in construction for over 25 years and started specializing in new construction forgetting my renovation base. Everything was great, great money, until 2008.
Thanks for the input. This company has a source currently and I've explained clearly that I will have to take slow steps into this.
Larry, what is the bet that those same companies would have had locked in supply contracts to provide them with some degree of surety in their business planning while leaving you swinging in the breeze?
@@markfryer9880 Companies are run based on maximizing profit. Their managers are rewarded for that.
Cast iron cookware can't be beat for cooking with. I bought a cast iron corn-stick pan on our honeymoon in 1971 and we still have it.
That was a delightful episode. Good luck with the new venture.
Great video. Wonderful you got to introduce new folks to casting, and you’ve got the chance to scale up and turn your passion into some dollars.
Great Wife, good neighbors. Happy Man.
No kidding. Congratulations on y'all's wedding anniversary.
Good luck with the new venture.
Great story.
That looked some good pizza there, at the beginning!
My brother used to be involved in a reasonably high-level die-casting facility. I visited a time or two, no expert at all. They were casting some high-precision parts with lots of detail. This was quite a while ago, but I recall the machines were perhaps 30-35 feet long and the dies were massive blocks of tool steel about 30" x 18" x 5" thick. I believe they had water passages for cooling. The precision machining on those dies was just incredible. They needed a forklift to move them on and off the machine. The molten aluminum charge was rammed into the mold at VERY high pressure, and on the parting line, all the walls and ceiling had a line of aluminum that had been sprayed. Just sayin', I hope you can do your diecast work you want to do with just gravity feed, without needing a $250K machine.
Thanks, so far I have been able to avoid getting in debt by building what I need.
I am actually aiming for injection not gravity along with water cooling for the dies.
Clarke, Awesome video, great content, enjoyed watching and hearing from your neighbors, the making of a skillet for their wedding anniversary, a great idea, thanks for sharing your video.!.!.!.
Thanks Jerry
Just found your channel. You can thank/blame Keith Rucker. Enjoyed the video, thank you for taking the time to make and post it.
love the story of the neighbours! I entered Keith Fenner's WIYB 2016, and another Australian entrant was Fred, entered by Bruce Whitham, we got to talking and found out we live less than a mile apart, met all the way in the US of A! :-)
Funny story JB, yes that's a long way to come and meet neighbors
your supervisor must be a real taskmaster
this is great - i can't tell you how complicated life has become since my step pulley got stuck in the washing machine
GREAT VIDEO!
Enjoyed both projects. Love the idea of the anniversary skillet and wish I lived closer. We've been married 52 years and if nothing else I'll cast a 53 year brick for my wife. Door stop, chock for when I have to jack up the car, or if I make it big enough a hot pan holder! We'll see but it won't compete with those cast iron skillets. Greg
Gregg, congratulations on your long lasting marriage👍
Laughed my head off at the distance to your neighbours place. That’s priceless.
Good luck with your new venture / adventure.
Looking forward to seeing what ever you are allowed to show us. You can pixel out the classified stuff :)
Great video I was wondering when the fire brigade was going to show up all the best to you and yours
I'm so glad you said that sometimes it takes two or three goes to get a good casting. I struggle with the expectation that every mould yields a perfectly sound outcome. It never seems to work that way for me but UA-cam would have you believe otherwise! Good luck with the new venture😀👌🇦🇺
Hey Presso!
Mark it is rare that I don't have to recast a one off piece. I get lucky sometimes. Production jobs are entirely different of course
@@windyhillfoundry5940 It's bad enough having to wait for a mould to cool down when working with aluminium only to find the casting has failed. It must really suck when you have to wait around for an iron pour to be revealed and it's a dud. I get what you mean about production moulds. You must be able to dial in the process early on and then get reliable results.
Regards,
Mark
Nice, Clark.
Hello Clarke, another great video on casting a stepped pulley. It is interesting to see the care you take to get the best finish on the casting. It made me laugh about Chad and his wife only living 3 1/2 miles 🤣 from your workshop, glad you could help them. Hope the contract for the alloy castings comes off, for you. Please keep your videos coming. Best wishes stay safe Geoff Lewis, Wales, UK 🏴🏴🏴
Thanks Geoff, yes what are the odds. They moved here just recently so it is a small world
Always a pleasure to watch a master do his work and magic.
I'm an earthquake fellow, myself. Tornadoes scare the beejeez out of me. Congrats on the new client!
me to but fires are getting to be a thing now as well
Clarke, looks great! I can't wait to get it on the lathe! Thanks again.
It's coming Brad👍
I really enjoyed this video. I'm excited to see your die casting.
Me too, just hope things are simpler and not harder😞
As always, a great video Clark, you have an excellent channel.
Thanks👍
Congratulations Clarke on your new venture, I hope you make a million dollars on the project.
Oh me too😁
Enjoyed your video and I gave it a Thumbs Up
The Pully came out great. I like the fry pan idea, nice to have good neighbors.
Thanks Randy, yes these people bought a place nearby just recently and it's ironic that he'd set out looking for me only to discover I'm right down the road
@@windyhillfoundry5940 love it.
@@windyhillfoundry5940 It was a very good little chuckle to find that they only had to travel 31/2 miles to your place.
on the 1/4" die grinder your wife was using at the end.. if you have a lot of heat build up in the die grinder.. at a shop i worked at a took some ABS pipe and made a holster for it using the hot air gun to assist forming it. but i had designed it to hook to the shop vacuum. . this allowed me to put the hot die grinder in its holster and turn on the shop vacuum.. the die grinder would be cooled and ready to use again in just over a minute. just a thought.. sorry no pictures that happened back in the mid 90s and i did not have a cell phone or camera back then.
Thanks for the tip Wayne👍
Nice video
Congratulations on the new the new customer! This part came out great Clarke as always thanx!!😊👍
I love the Strothers story.
Katrina was a hell of a ride . I believe I showed you how it moved my shop 1/4 of an inch . Looking good Clark 👍👍
Thanks Bill and yes. It also shifted our house a degree or two
I enjoyed your great video. I recalled my casting days in the Navy. I’m in Brandon. Would love to visit your foundry.
You are welcome to come by anytime. Just give me a days notice👍
Glad to hear that your business is growing. You are a lucky man to have such a helpful wife.
A favorite one. Thank you from Huntsville Alabama!
My neighbors actually migrated here from that area
Thanks for sharing Clark! Congratulations on getting the work.
Thanks Craig 👍
Very neat, thanks.
Here in the UK, we caught the tail end of Katrina, and I crossed the English Channel, on a Ferry, in it.
That was fun, at least for those of us who don't get seasick.😊
I actually rode one of those air boats from Dover to Calais back in the 90's, it was a frightening ride for me on a calm day🤣
@@windyhillfoundry5940 Piece of cake, even in the tail end of a hurricane. 😁
Mind you, I can't speak for the three guys talking on the porcelain telephone, or the girl who was whiter than a sheet of paper.
We had a crossing of Bass Strait going to Tasmania for our Honeymoon back in 1999 that caught the tail end of a cyclone that had clipped the bottom of Western Australia and petered out in the Great Australian Bight (sort of). It was a very rough crossing even by Spirit of Tasmania (1 or 2) standards and there was at least one woman still in hospital in Hobart a week later due to dehydration from throwing up excessively. I know that my vision took a week to settle down, the tiles in the shower were shimmering the next few days.
I wonder if one of those pump up spray bottles (for plants and stuff) filled with water would help on the mold...if the metal oozes out...shoot it with a mist of water, instantly cooling the molten leaky metal to form a plug and have the ability to quench the fire...I heard the only danger of water with molten metals is if the metal is ON TOP of the water like soaked into concrete creating a steam pocket thus making it explode (shooting molten metal all over), water on the surface would just instantly flash off and not create that explosive mix like with concrete...just a thought
Either way...loving the video's and might need to hire a hand or two to assist with the high volume stuff in aluminum...mooovin' on uuup!!!
Keep em coming!
Thanks Brian and yes, you are correct about water trapped under iron opposed to water on iron. As for try to freeze it when it first blows, banking it with a shovel works but since I'm often by myself and in this case where it blew out two sides, I'm still holding the crucible pouring.
Got to say, love the work and explanations of what's going on. Glad you're picking up some non ferrous but sad you can't share what you're gonna be doing. I really wish Martin could help as olfoundry man is probably the most knowledgeable I've ever seen in production work in a small foundry.
Looks like you're gonna have to get a foundry helper so you can focus on the good stuff.
Good luck, don't forget about your small customers, be safe and thanks.
I would say that Martin would have knowledge of the process from his previous employment in the Automotive industry here in Melbourne, Australia. He currently is only set up for small scale gravity die casting and has a video showing its use.
That's my kind of supervisor.
Yes, and he's nearly blind and deaf so he misses out a lot on his surroundings
lt sure is fun to watch you cast stuff...Good luck coming up cause you might need it....Thanks Clark...!
Thanks Steve
Nice job & met neighbors too. Trying to get Mary to paint my square re white & blue. It came out nice.
Mike I'm anxious to see how it turns out
Nice
Enjoyed your video, I live near johns, right down the road from you,more or less
Hi Tom and yes, you are right down the road. My first gf lived between there and Puckett 😁
Thanks for the video Clark. Good luck on the adventure with the aluminum parts at least it melts at a little lower temperature. Glad you didn't get any damage from Delta. What a coincidence he had no idea where you were and was only 3 miles away. Give Dollar a pet on the belly for me. LOL.
Will do and yes what's the odds right🤣
Hello Clarke I love the name "Doller" what a cracking name that is and he's a labrador one of my favourite dog's 👍👍❤. Best wishes, Geoff Lewis Wales UK 🏴🏴🏴
Dude! I'm so happy for you! High volume is good, but remember to keep some time for yourself. Can't wait to see what's next!
I never have had time for myself so I'm used to it😁
Cast iron pingpong paddle!
...at 17:49...thereabouts.......must be a SUPERMAN's Dog (DAWG) to Supervise (SUPERVISION) with eyes closed !!!
Had to unplug earphones just so wife could hear Strother story. LMAO! 3-1/2 miles? Clark, you are right. What are the chances....?
I know right🤣. They only recently moved here
I saw your comment of Keith's site. Maybe a solution to all the bad patterns is to make a pattern specification sheet that goes to people making an inquiry about getting castings done. I do shade tree aluminum casting for fun. So far I think I've made most of the possible mistakes. Most, not all!
Larry I plan to do a video of making patterns to cover all this eventually. Finding time to do it has been a problem latley😞
@@windyhillfoundry5940 Maybe as part of the video, images and instructions that they can screen grab, print and carry to the work bench? Memory being what it is. My first attempts at cores weren't even close to good. Olfoundryman has some excellent videos.
UA-camr "Olfoundryman" is an aluminum expert (small production). Nice videos, very informativ. Maybe interesting for you. Best Regards
Yes I know Martin well. He's the best molder I know.
@@windyhillfoundry5940 He is a top bloke, highly skilled but modest, and prepared to share his skills and knowledge/experience with us on UA-cam as his way of paying forward his skillset.
clark your shops on fire there around 12:00 in :) lol just another day in the foundry
Yep, I'm immune to blazes now😁
@@windyhillfoundry5940 next thing you'll be barefoot like the guys I see In India
Good luck in the new venture. Business seems to be really growing! I hope it’s going the way you want it to. Looking forward to seeing what die casting actually is, since I have no idea what that means. BTW, does the sand ever go bad? Contaminated or heat treated or some such?
Thanks Glenn, the sand developes ash which has to be separated yearly. The sand is for the most part permanent, clay has to be reconstituted over time
Recently discovered the channel. You do an amazing job. What kind of setup do you use for melting iron?
Thanks, I currently use diesel for the furnace
I wish I lived 3 miles away! Some people have all the luck🤨
Is there a possibility of seeing that pulley being machined?
I am the customer for that pulley. I will definitely get video of it being machined. I am restoring a Hardinge TM milling machine and that is one of the pulleys for the table feed that broke during disassembly. I have hours of video of the project over the last two years, but i've never edited it. One of these days!
@@bradhayworth2926 Looking forward to seeing that.
I don't know if the customer has a channel
Can I make make a business suggestion? If you were to get set up for 3D printing, someone could send you a file, you could print then cast it and return the cast item. No reason why you couldn't send internationally also if people are are prepared to pay postage. It would open up the whole world for your business. I would use this service so I imagine others would also. Great watching your work, learning a lot!
Hi Matt and thanks, If I buy any 3D machinery it will be a cnc router. I have no need for a printer. Routers leave very nice machined sides and printers leave a laminated surface that requires days of painstaking sanding just to get it to release from a mold cleanly.
The plan is to install a cnc router but I'm taking small steps in that direction and I am struggling to keep up with jobs the way it is. I can't find good help around here so I have to be content at this speed for the time being😞
@@windyhillfoundry5940 Understood, just a suggestion. I would be interested to know if a SLA printer would create prints smooth enough. Something like the Elegoo Saturn. I think it probably would be OK.
Great video. I caught wind of your channel from Keith's. I was wondering, that locomotive wheel your wife was grinding on - how much do you get for a set of those? Say I needed six and they're about 12" in diameter? Round numbers. Thanks!
Thanks, you can contact me at clarke@windyhillfoundry.com and provide some drawings where I can give you a quote
LOL...I didn't think Keith was a licensed electrician either...LOL...Sorry, that was funny. :)
I'd trust his wiring before I would mine😁
Hey Clark how do I get a hold of you? I'm needing some small flywheels cast for some small steam engines. I can 3d print the pattern. Do you have any specs as to what the pattern needs to be like in order for it to be cast?
Hi Jeremy, you can contact me at
Clarke@windyhillfoundry.com
Do what you gotta do to enjoy what you love doing. The ride is short, no regrets at the end. How's dollar?
Dollar is on my last nerve but she is at least learning how to jump in the glider and rock herself. I'll have to get that on video
Puppies will be puppies.
What are the chances of eventually having serious competition to your foundry just down the road?
Trevor I would gladly welcome it. Too much for one person here. Truth is, many don't want to work like this, not many want to learn this much and not many are up to getting 3rd degree burns often. With no past foundries in this area, no one has any experience remotely close to what is needed to get any major competition started.
Was wondering what the percentage is on your ferro silicon? I have found 15% but I was told 75% is better when working with brake rotors for my iron supply. I'm wanting to cast some cookware and would like to have a good grey iron when finished. Do you have any suggestions or recommendations?
Thanks for the any help and advice you can throw my way
Be careful about what others tell you. Some will set you up for failure. That's way to much, I use no more than .025- .050%
No ferrosilicon is better than too much.
@@windyhillfoundry5940 thank you
Your castings look fairly dark for grey iron. I am guessing your carbon content maybe creeping up.How often do you do break testing on your melts? May try adding some magnesium or pure iron if you can find a source to your mix. I think this would help to reduce the hard spot inclusions you sometimes get as well. Could be a result of the furnace atmosphere as well particularly since I think you are diesel fired, you could be pulling carbon from the fuel as well. Not sure it would help but maybe add some lime? I assume you likely already do.
Brian that's the patina from stress relief
@@windyhillfoundry5940 Makes sense!
Couldn't you cast the rough grooves in the pulley by splitting it in half and molding it on the side.
I believe this will be a flat belt pulley. I have cast grooved pulleys before that are split at the v
@@windyhillfoundry5940 Gotcha- like an South Bend 9"
That's not a cold shut, it's a spoon rest! 😁
🤣 see I did it right to begin with
@@windyhillfoundry5940 A guy who works for Lodge was telling me they make theirs with spoon rests too sometimes - they just don't sell those ones is all. 😁
I had the same thing happen to me trying to copy you and Cast Iron Gypsy!
Be careful local fab shop went under due to them 90-180 day "delayed " payments policy.
Living on the edge is hard to avoid doing this
When I was in business as a Joinery shop, I also had payments "held" for really unfair times, the big companys play this game quite a bit, at the expense of the little business. We were very careful with our money, no thanks to the big companys. Please be careful and aware Clarke. Best wishes Geoff Lewis, Wales, UK, 🏴🏴🏴
What are you doing step pulley!?
You'd have to ask the customer that one🤔
Where's Bri at these days ?
She's back in school
ol' dollar seems to have gone white and got old!
Yes Jake is the white version of Dollar😁
What? No "I never knew my real pulley" jokes yet?