6x6x3 MACHINIST BLOCK

Hello my friends, this is a molding, remolding and remolding video that finally turned out. I did have issues at first but the end result turns out beautifully. Yes, I had to trim a lot of video for this as it took 3 attempts but as I specify in the video, there are plenty of challenges that go into molding.
Check out the below link on the USS Pueblo. Rest in peace Tuck.
• Remembering Vietnam | ...
Grinder, grinding wheels, cutoff wheels, burrs and rotary stones along with grinder furnished by SUHNER.
Jarrett Gray www.suhner-abrasive-expert.com/
#windyhillfoundry #castiron metrology #foundry #ironpour #madeinmississippi

[@fpoastro]

"Im not chargin' enuff guys"... you hit the nail on the head there.

[@1982MCI]

Can we ever charge what we should on custom stuff like this tho? While I don’t do casting work (but would love to do it) I have done other custom, one off type jobs that takes an equivalent amount of patience and investment and I’ve always felt that if I charged what I’m truly worth, I’ll send all the customers screaming for the Appalachian hills and I’d never see em again, even for small, reasonable jobs. So I tried to price things where I still made money and didn’t send them to the hills. I’ve always looked at it this way, some things are done in life for money and you can build a nice comfortable bank account but then some things you do for the love of what your doing while also possibly trying to keep a dying art from our countries deep history alive despite not being able to get rich off it, it’s more for the personal, creative satisfaction of manufacturing items like this that not many guys in the country can do at all anymore, and actually, are probly much too lazy to learn or do hot, heavy labor like this nowadays. We live in an instantaneous society where everyone orders something online and it’s delivered tomorrow if not same afternoon. Pride and personal satisfaction from the local town craftsman is dead and that’s kinda where I rank what he’s doing. If you can cover your costs and make some profit, then I was always good with it. Money has never been a big motivator for me, it is evil but a necessary evil so I made enough but the satisfaction I got whenever I had a customer jumping up and down with excitement because they loved it was a bigger payoff for me than just having a big check. It’s a very tough line to balance tho and will drive a guy absolutely mad and right out of business if he’s not careful. He may have a completely different view point than I but this is only my opinion after 40+ years of trying to balance. Personal satisfaction to me outweighs money any day as long as I’ve got enough coming in to cover all costs Take care and be safe out there brother!

[@fpoastro]

@@1982MCI Im about 3-5 years behind you at 35 years in the muck, commcercial CNC millwork preceded by GC work. I completely hear you with regards to trying to be "fair" and being fearful of chasing off work but that is most often a rabbit hole that points squarely to the bottom. Its a luxuriously enjoyable position if your able to survive while doing it but typically in the end its not even surviving. Most people in my Appalachian world can afford to pay what the hourly rate should be and often times earn far in excess of that in their day jobs (union pipeline, corporate work, whatever) and most would, and will, go to the box stores over local on smaller work even if your competitive. I agree its a very difficult balance but its a better balance to find as early in the process as humanly possible. A job like this with owner supplied molds would be a perfect place for a clause in the contract that states a one time non refundable ramming attempt will be made and if it is unsuccessful due to the mold they will be returned or re-worked at an hourly rate. I can only imagine Clark has a conversation with the maker of the molds that xyz issues will require xyz of work at xyz cost. Hopefully he's not re-working the parts for free. I have no idea what the cost to the customer would be for the single square in this video but I would hope its close or above the couple hundred dollar range with time, materials, fuel, and raw materials. A single part like that in my world, with a spare, would be a very expensive endeavor. Its the reason why you see shop rates posted in mechanic shops. Its just what you need for basic survival.

[@murph7591]

I have never done any casting , but Clark, we've all gone through mishaps, keep up your fantastic videos!!!! Ty Dan Murphy your Canadian friend!!

[@Preso58]

I would not have thought those patterns would be so hard to extract. I felt your pain when the first cores broke off. Sad face. 😔

[@jdmccorful]

Hand work seems never easy. Takes a certain kind of person to pursue it and do well and I think you have those skills. I always enjoy our time togeather. Keep on keepin on. Thanks for the look.

[@ypop417]

Clark amazing how something so simple can be so compcated

[@MrPossumeyes]

That moulding was hard work, Clarke. Glad my words of encouragement helped keep you calm and smooth.

[@mce1919A4]

Nicely done.

[@floridaflywheelersantiquee7578]

Thanks for sharing

[@martynbuzzing3327]

Fine job my friend. Broken machinery is part of the business but a pain all the same.

[@RRINTHESHOP]

Nice spacers Clarke.

[@kimber1958]

nice job clark.

[@robertkuipers9422]

You have more patience then i do.i would have thown the mold across the shed by now..😲

[@evanpenny348]

Really enjoying your videos. By the way the Coanda effect is really similar to the chimney effect where a rising current of warm or hot gases will tend to "stick" to any nearby vertical structure, like a chimney for instance, or even a person standing near an open fire. The smoke seems to seek out any person standing nearby. Annoying really, but basic physics; the fire sucks air into itself for combustion, creating a suction effect where air all around the fire moves inwards. By standing near the fire your body interrupts the flow a little, meaning that more air goes to the fire from other directions. This pushes the smoke in your direction, and seems to "cling" to you. Fascinating that this effect is noticeable with pouring molten iron into foundry molds. All the best from NZ

[@llapmsp]

Awesome job Clark. What persistence and patience. Qualities that are hard to find these days. Great video, thanks for sharing.

[@calvinjutila8270]

Merci sakes! Its hard to breath while you are trying to get the the mold cores out. Patience certainly is required. Anyhow, great work.

[@wb8ujb]

Thank You for sharing the video. I appreciate that you take the time to publish these.

[@canoflage]

Good work thank you for sharing your knowledge

[@rogerohlsson2336]

At the 26:37 mark, you have a good illustration of just how much shrinkage occurs when the cast iron solidifies. Looking at the pouring basin atop the sprue, the bowl shape is clearly evident. Great job of pouring, Clarke!

[@davidzeak8667]

Love your videos Clarke. I'm a novice metal caster and thankful for your willingness to share your knowledge. Thanks!!

[@mattthescrapwhisperer]

A class on utility knives; my oh my.....That grinder is a beast!

[@cripplecreeksawmill]

Beautiful job Clark, your videos/posts are always a treat👍

[@stime6472]

My wife and I have our own business manufacturing tinplate cookie cutters. And like the the two of you we have our ups and our downs. It is well worth all the time and effort that we put into it and we wouldn't trade it for all the tea in China. Best of luck and keep up the good work. Remember the hardest taskmaster you'll ever work for is yourself

[@johnmccanntruth]

Those turned out really nice. Just saw a video this morning where the gentleman pressed 3 nails down into the core, like you mentioned the screws, to help hold. It worked, but I don’t know that it was the key. His pattern was much thinner…

[@erich9244]

Persistence pays off ! Nice casting indeed someone will be very happy to have these once they are all good to go :)

[@murph7591]

I'm with you , we have garden snakes up here , just let them do their business.

[@SolidRockMachineShopInc]

Nice job Clarke!

[@donnywt3195]

Great job Clarke.Looks like the old grinder is running good

[@tobhomott]

We get them here too, but up here they actually do wait til June to appear

[@1982MCI]

He’s in Deep South tho so it’s pretty common for them to appear in April and may in parts of the south

[@tobhomott]

@@1982MCI yeah, I know he's in Mississippi. I'm up in Canada fwiw

[@nigelleyland166]

Parting dust, I'm still using cheap talcum powder, smells lovely! For the aount of casting I get into, it will do! LOL Would a greater interior parting angle help to retract the pattern? I have to say, regarding casting faults, I have seen far worse in Land Rover engine part castings. Yous quality control is Unserpassed. take care and thank you.

[@bcbloc02]

Take more advantage of the cut off wheel over grinding, it is way faster and less fatigue on you since it bounces less.

[@kmcwhq]

I think a large industrial class chop saw would save him much time. And hand grinding

[@DavoShed]

Great video as usual. Love to see your shaper running and a finished product even with a few holes. We call those Bugs Christmas Beatles. I’m sure you can guess why.

[@aleksandarvasilevski7410]

Coanda effect, molten iron is also fluid, difficult to believe but true.

[@stxrynn]

We called the brown ones tater bugs. And those jeweled scarabs were what we called june bugs. Bugs is bugs when they pop. And I bet they make a real mess turning to steam in a split second down in the mould. Take care!

[@Narwaro]

Yeah yeah draft angles in the design makes life way easier when making the molds

[@TgWags69]

Those are June bugs....up north 😉👍

[@neffk]

About the safety class for the box cutter... there is some scientific evidence that we're getting stupider. Sort of an Idiocracy type situation.

[@MrPossumeyes]

It's because of the safety culture that everyone's pushing: in the past the stupids killed themselves and each other off, now they can't and they're reproducing. When I was kid in the playground if I made a mistake on the swings or monkey bars I would land on concrete at the speed of gravity x mass - now the kids bounce and land on their feet (if they're clever) .... or not. Then they get rushed to the ER. When I was a kid if we got a blood nose we'd stuff an acorn up there, none of this "Ooh, let me bandage it for you" nonsense. And knives? We learnt about knives the proper way!

[@glennmoreland6457]

Good

[@Xlaxsauce]

Those basic training classes for tools at work goes to show how many people never have to lift a finger or refuse to think. Like what possible problems can occur. I've seen far too many people who use say wire wheels without a guard, glasses and operating it inline with their body. Common tool common problem of wires flying off and piercing a person.

[@CatNolara]

Despite the struggles they turned out really well. Might propably have helped to have less steep of a draft angle on the inside of these, as well as the round holes. Btw I'd love to see one of them getting machined on a shaper. And those beetles look a little bit like the "Maikäfer" (may beetle) we have over here in germany, don't know if they live in america too though.

[@Toolman22364]

Luking Good My Friend .

[@mdouglaswray]

Funny how something so apparently simple could be so hard to mold!

[@fpoastro]

Know you likely dont have one but would a decently setup band saw make very quick work of lopping off those gates and lugs as opposed to the hand grinder?

[@stephensarkany3577]

Until you cut a sand inclusion or even just a few particles in the surface & trash a $50 blade

[@Farm_fab]

Clark, I'm just wondering if a metal cutting saw like an Evolution would work faster than grinding to cut off the excess?

[@NP-rh3dt]

I think holding the work piece would be a problem. I work at one of the largest grey iron plants in the world and we use grinders. The gating is specifically engineered to break off in shake out but the risers left over are ground down.

[@keithgutshall9559]

Making patterns seems to be an art in it self. Getting it to release it from the sand the draft angle has to be just right.

[@markfryer9880]

Well, that is because Pattern making (metal trades) was and still is a separate and distinct trade all by itself, that required a tradesman of considerable skill as well as mathematical ability. In older days the patterns were made of solid durable wood in order to survive and be repaired from the rough and tumble of life in a casting foundry. The patterns had to be made just slightly bigger than required in order to account for the shrinkage of the particular metal being poured for the part. The pattern also had to be able to split apart to help with raming up and to take any core prints and false pieces that maybe required to make up the eventual shape of the casting. Radius edges and draft angles were required to ensure clean separation between the casting sand and the mold pattern and its easy removal prior to closing the mold and pouring.

[@steveshoemaker6347]

Looked like you coated them molds in graffiti to me😅...Clark it is always good to see you👀 and you are looking well 🙏...Love your video's cause l cast a lot of stuff my self but in gold.....Thanks my friend....Shoe🇺🇸

[@sylvaingervais247]

BONJOUR JE PEUX VOUS DIRE QUE TU FAIS DU BON TRAVAILLE TU A BOUCAUS EXPÉRIENCE JE VOIS QUE TU UTILISE GRANDEUR POUR ENLEVER BARRIÈRE DE COULER ET LES MONTER DE MÉTAL 1 TU PAIRES BOUCAUS DE MÉTAL ET TU USE DES PIERRE 2 TU COUPE AVEC UNE SCIE A RUBAN 3 TU RÉCUPÈRE TOUX LE MÉTAL POUR REFONDE MERCI POUR LES VODÉO DU CANADA BONNE JOURNÉE A TOUS HELLO I CAN TELL YOU THAT YOU DO A GOOD WORK YOU HAVE LOTS OF EXPERIENCE I SEE THAT YOU USE GRANDEUR TO REMOVE BARRIERS FROM FLOWING AND MOUNT THEM WITH METAL 1 YOU PAIR METAL BOUCAUS AND YOU USE STONES 2 YOU CUT WITH A BANDSAW 3 YOU RECOVER COUGH THE METAL TO REFOUND THANK YOU FOR THE VODEO FROM CANADA GOOD DAY TO ALL

[@paulsilva3346]

How about using an electric engraving pencil on the ends of the 1/4" dowel rods, pushing down. To vibrate the dies.?.?

[@timothylangley6945]

I'd be upping the charge, or getting new moulds made.

[@dougaldhendrick3497]

I would be trying a spray putty (car finishing) on patterns, thin it to just past before water consistency, dries very quickly and rounds of everything.

[@edparadis1578]

Good work. What are you using for your sand mixture? Thanks for sharing with us!

[@paulhatch7759]

so much fuss over what appeared to be a simple part. well done.

[@Digital-Dan]

I found myself inventing little four-tether micro-winches to lift those patterns straight up. And maybe an electro=mechanical vibrator thingy. I would spend more time building things that don't work than actually doing the job, if history is any indication.

[@nashguy207]

Itn seems like you just can't keep everything working like it should. If its nor the muller its the furnace or something else. Love seeing your work!!

[@highlandermachineworks5795]

My friend works for a company that is Canadaistan owned. He said that the not only do you need a class to operate a utility knife, but you're required to be wearing cut resistant gloves prior to, during, and after use of your utility knife. However, if you wear out or cut the gloves you're going to have to wait until they can be replaced with the next months budget. Mind you it's a 3.8 billion dollar company. When he tells me these things it reminds me of the Imperial Chicken Processing Plant fire of 1991. (25 dead because they were too cheap to get a new hydraulic hose made. So they Jerry rigged one from worn out old and spare parts.)

[@jbkbrand]

Love your stuff. 1 question. Can you use a graphite powder? And please with all my heart this suggestion is not to be intended to be funny, sarcastic or porn. My wife got the idea from a vibrator we use on her shoulders to separate clay molds for her ceramic stuff. Yes, Amazon sells them. Variable speed, precise target area. If y’all can get past the kinky part it works great.

[@Thrallbra]

Grafite is used in some parts, that’s a good idea, but I really don’t know any better how it would react to oils in the sand and the surface of the cast part. Even if it doesn’t work would like to see a part done with it to show why it doesn’t work

[@lance9101970]

Clark on the parts that are hard to release could you drill the pattern and use low air pressure to help you lift it from the sand.

[@martineastburn3679]

Wonder how air scaling needles vibrating on the top - might create a good racket someday. Just a Thought.

[@stancloyd]

Looks like the patterns need to be screwed to a 6" faceplate on a wood lathe and recut the core hole with the proper radii. The pattern obviously has enough draft built-in but is the surface-finish as slick as snot on a door knob?

[@markthompson8656]

What ever happen to your new antic furnace? What progress on it?

[@qwerty3663]

Do you ever go back to the client and ask for yield increase changes like in this case perhaps asking for a larger draft angle?

[@stancloyd]

My chop saw would make short work of those pesky sprues and risers.

[@stevensexton5801]

How long do you leave the castings in the kiln at 1400 and do you let them cool in the kiln?

[@ralphjones7240]

Would additional mold draft assist in pattern extraction?

[@peteengard9966]

I had complete faith in you.

[@craignicholson505]

Have u ever thought of using silicone spray for a nonstick on the moldeds Used to use it for high pressure polystyrene moldeds U need to let it set thou for 24 hours

[@Newmachinist]

Hi Clark - are you going to the summer bash??

[@dennissheridan1550]

Clark, Why it is that you don't any powder on the first side you mold up, I would think you would want it on both drag & cope sides.

[@AmateurRedneckWorkshop]

Great looking castings. I think you do too much work cleaning them up. Seems like that would be the customers job. I killed 8 baby snakes on my driveway so far over the past month. I made good snakes out of them. Seem like I get a new batch every year so the momma must be living around here someplace, makes shivers go up my spine.

[@bobdouglas262]

I wonder if using cores might have made the job easier?

[@nilzlima3027]

Clark: is this something you are willing to cast for others? i could use a couple of those things.

[@mikediamond1522]

I'm not knowledgeable of anything here but I feel the pain. Is it possible to heat the part with a heat gun or torch which would expand the part then let it cool to pull naturally away from the sand barrier? Mike

[@matslundberg1289]

no parting dust on the core, ccould be why it doesnt part.

[@scaletownmodels]

Howdy. I'm a home machinist and have parts I'd like to have cast someday in iron. If something this size hadn't been a pita to remove the patterns, what's the ball park on something like this? This is for a one off type of part (or maybe two or three). I've been searching and I see mentions of $2-$3.5/lb then they say how many tons are you doing. It's hard to find examples and when you're a hobbyist you're just trying to get an idea if what you want to do is feasible cost wise before you get too deep into planning. I see plenty of home shops casting like mini lathe beds and parts in aluminum but with iron you're talking another 1000 degrees of trouble. I can model up some ideas and get the weight from the cad package easy enough if going by a per lb price gets you in the ballpark. Anyone know of a site they can point to that has examples of different castings and approx costs?

[@1crazypj]

That was a lesson in patience. Would have been real easy to just say 'F***it' when the centers were breaking out

[@alangknowles]

Does she know you are using her best makeup brush?

[@1982MCI]

She probly will now, lol

[@stephensarkany3577]

What is the release paint called? Is it zip slip?

[@davidapp3730]

Is it possible to make a 4 part mold? So you could pull the inner section out first then the outer section.

[@royreynolds108]

It is possible but a whole lot more complicated and harder. Sectional molds are necessary for very large castings, like ones that are in the floor.

[@akfarmboy49]

will those 6x6 block for sale, looks like pattern needs more draft.

[@willydoitbettydont9100]

The box cutter class is probably more the insurance company they use than them, unless there are that many ......... in your area.

[@mdouglaswray]

Have you ever made meat-tenderizing hammers?

[@TheMadJestyr]

I think a bandsaw would work better remove excess material from the casting. Maybe I am missing something.

[@johnlanham9057]

25:21 what’s the $$/hr start pay. That might tell you why they’re getting people who can’t get thru doors & around corners 0k … 🤷🏼‍♂️🤷🏼‍♂️

[@pbysome]

Is there enough draft on the molds?

[@WreckDiver99]

@25:12 It's not the people that they are hiring, it's the lawyers that seem to find new ways to file suit to make somebody (and themselves) a lot of money. "Lawsuit Prevention". I had to take a class in using "box cutters" along with proper PPE (cut resistant gloves, eyeglasses, long sleeves and long pants) back 30 years ago. As the "safety" guy said when he walked in; "thanks to a bunch of whiney babies that cut themselves by being stupid, then blamed the company for it you get to take a class. We are not willing to spend another $150M+ in lawsuits for idiots. Therefore you get to sit through this class, take a test, and prove you know what you are doing. If you can't you won't be able to have ANY knife on your person, including a pocket knife. If after all of this you still are an idiot and slice yourself up, we will let you bleed out". LOL. Yep...welcome to the USA where we have lawsuits filed by idiots, for being idiots.

[@clydedecker765]

Seems like you do gave your share of equipment problems. Maybe those bugs are gremlins in disguise?

[@gregorythompson2251]

Do you sample your iron to check chemistry ever.? Just wondering

[@CarnivoreCurin]

Safely classes assure asherability. In the event someone cuts their hand, the company will have proof that the user of the knife was competent and trained to use the knife.The classes are not required because someone is stupid. So don't be offended. Take the class, make snide comments, and pick on some new hire.

[@7311andrew]

Try using spray silicone release spray designed to make bread release from the mold.Is is slippery as Owl poop.

[@youceftekfi5547]

But What is this?

[@surlyogre1476]

These are raw castings to be made (machined) into "machinists' squares". For more information on "machining" check out Clark's friends, Adam Booth (Abom79) and Keith Rucker (Vintage Machinery). But, I think these are going to different machine shop for finishing. edit: "Fireball Tool" does a lot with machinists' squares of various types. Check out his channel, too.

[@steveharmon4518]

The class isn’t to teach you how to use the knife. It’s to give them plausible deniability. After all you can’t spell who cares without “HR”

[@danh0369]

But the problem is plausible deniability is a bigger deal than common sense and reasonable expectations