Everything Man

Random projects from an alchemist's workshop.

Monday, 25th April, 2016

This post is part of a series on making and using the Gingery Foundry.

We got a foot of snow last weekend which put a damper on my foundry project while I waited (impatiently) for the yard to melt. This weekend I was able to get back to work. The next step in putting together my foundry was to blend up some molding sand. This is a clay-bonded sand mixture designed to hold its shape when packed around a pattern. The synthetic sand recipe I used should ideally have the following proportions (by weight): 91.5% fine silica sand, 7.5% powdered bentonite clay, and 1% wheat flour.

Tuesday, 12th April, 2016

This post is part of a series on making and using the Gingery Foundry.

The principle behind metal casting is simple: heat up metal until it’s a liquid, and then pour the molten metal into a mold. The mold itself is usually prepared in one of several ways:

Green sand casting involves using a wooden pattern blank. Molding sand is packed into a frame around this pattern, and then the pattern is removed to leave a pattern-shaped void in the sand. Molten metal is poured into this void to create the cast part. The shape of the part being cast is constrained in some ways, since you need to be able to remove it from the sand without destroying the mold.