Casting an 800lb cog!

[@Ididathing]

Very interesting video!

[@toddi4life819]

What did you do

[@Coloneljesus]

How ya going?

[@implausibleimpossiblehypot4006]

Yeah what did you do ?

[@owainrichards4372]

Next idea for you casting

[@watchpeasant6856]

Haha love ur vids mate

[@Phil99330]

If you go through Switzerland, you should try to reach out to Charles Roulin a master engraver on knifes (blades and handles). The engravings are amazingly detailed depicting mainly nature/animals... ;)

[@os4b4]

To add to that, Switzerland has still a (relative) lot of specialists that cast cowbells too

[@Phil99330]

@@Dockhead bla-bla-bla 🤦

[@ritzyorangutan]

@@Dockhead you're the bore

[@baileyjerman5573]

Do you think he does commissions?

[@lundgrenbronzestudios]

Seeing Alec do the small amount of casting he did inspired me to start my own casting workshop, and my own KZbin channel. I really hope you visit some more casting projects in the future. This was amazing to see.

[@DerEineIch]

For your roadtrip you might be interested in the city Solingen in Germany, that is also known as the city of blades. It has a rich history in knivemaking and metalworking that goes back to the middle ages, some intersting sights (the german blade museum, a historical drop forge) and it's right on your route, between Cologne and Düsseldorf.

[@JamiePopple]

Awesome suggestion, I'll see what Alec thinks!

[@lukasgiese2331]

The annual knife market and exhibition will happen again after covid too. The biggest and best knife makers present their work in a museum that used to be a knife making factory itself.

[@fetzie23]

@@JamiePopple Can definitely recommend stopping by Wüsthof in Solingen.

[@onitramt77]

I agree, he really needs go there during his tour.

[@Malungeon18436571]

The route shown goes right through Solingen. It's maybe a little silly to think they hadn't already planned to stop in one of Europe's most well known blade production locations.

[@brianwingo6472]

I have been fortunate I my life to have done a small amount of metal casting and seen it done approximately 40 times. Alex used the term choreographed to describe the actual pour. As I was watching this I was remembering it was like a ballet. A crew as good as this has no wasted motion and is sure of the moves of everyone else on the pour. Work like this done at this level is truly a joy to behold.

[@eastcoastcastings]

Thank You Brian' Appreciate your words.

[@valentinmitterbauer4196]

Interestingly, the same thing can be seen at complicated surgeries, no wasted motion, a step- by- step- work approach and sometimes even markings on the ground for better coordination. In both cases, casting and surgery, you've got a delicate operation with a very limited time frame and little room for mistakes.

[@baseddino]

what kind of resin did you use in the sand? what did they spray on it to keep it from seeping into the sand?

[@piccalillipit9211]

*ABSOLUTELY BRILLIANT* The tour of Europe's workshops is an amazing idea *PLEASE MAKE THE VIDEOS LONGER FOR THIS WORKSHOP PROJECT*

[@danharrraka7578]

I'm pumped for the traveling series. This is going to be cool!

[@Seraphic85]

Used to do this on a massive scale for a company called Bradken. Such a cool experience when you have a 5T or 10T ladle hanging over your head full of molten metal filling 20/30 casts for mining companies. Awesome job showing off the trade Alec.

[@gordon3152]

I also have worked for Bradken foundries. I'm a Patternmaker. I worked for one in Scotland and one in Canada.

[@Seraphic85]

@@gordon3152 nice, always love seeing the patterns and watching them be filled with sand. Calming. I worked at Bradken in Western Australia, but it’s since closed down and moved to China I believe.

[@warbirdwf]

Good on you to get out and promote these still existing small shops in Britain and Europe. We need to support them so they stick around and not get closed and their work/production moved to Asia!

[@StarScapesOG]

This is crazy cool! People rarely think about the foundations upon which our society is built, thanks for bringing a portion of that to us!

[@heyletsplaythis]

I was going to comment but you nailed it. I agree 100%. Thanks Alec.

[@Leib33]

Don't you mean 'potion'? ? Because this is just magic!

[@arabonarocketcamel8352]

So much of the modern world is built inside foundries, makes me proud to work in one.

[@DiscGolfHunter]

Alec Steel just keeps impressing me and I love that he is not only spreading his own craft, but willing to get out there and explore and share other crafts that, without his exposure on his channel, may fall into oblivion. Well done young man. Keep up the good work.

[@MeriaDuck]

I ♥️ casting, in my distant youth, worked for my now retired uncle in his bronze casting shop on the weekends. I can just smell the sand and hot metal when watching 😎

[@driftwood89]

"Tour de Steele" sounds great - looking forward to it!

[@RumMonkeyable]

TREMENDOUSLY looking forward to your upcoming tour! Love the "how things are made" videos! Thanks, Alec and Jamie! 💕👍😎

[@AndiNewtonian]

Same!

[@tedf1471]

Very fine example of a cast sprocket. A cog is a single tooth in a primitive cog-wheel as used in medieval windmills usually made of wood.

[@rocketsauce8017]

Alec, I love all of this. Keep this content coming. If it’s molten steel,house demo, or just simple making/building. Keep doing your thing!!!

[@avoirdupois1]

Got goosebumps watching that big crucible decant into the ladle. So much liquid iron! The heat must be incredible.

[@Mobile_Dom]

i would be incredibly surprised if Alec doesn't get a small induction forge to work with the smaller rounstock and squarestock he works with just for the sheer noise and price savings

[@ChevTecGroup]

Ive been debating making one for that reason. And I don't hardly do any blacksmith work

[@loganhuwe9458]

he’s tried that before…. didn’t go well at all

[@ChevTecGroup]

@@loganhuwe9458 I'm guessing that it is hard not to overheat and melt the metal stock?

[@sigmasquadleader]

@@ChevTecGroup It's essentially a microwave for metal. The interior can be much cooler than the exterior, and you can start to melt the exterior.

[@D-Vinko]

@@sigmasquadleader If you use it wrong, you can produce this effect. Induction coils are used in commercial forging, and normal forging all the time. It's not even hard to avoid melting it; the depth of the heating is gradually reduced with depth (With appropriate settings), and the natural conduction of steel will even out the temperature. The center will never be "much cooler" when used correctly, because of the aforementioned natural thermal conduction of steel. In the video you're mentioning, he very clearly did not use it correctly, or adjust it's output for the application. It's like welding, you cannot just turn on a welding machine and weld any material at any depth reliably. The exact same applies to Induction Forges. The "Skin Effect" is reduceable, which is simply done by adjusting the frequency and power output. Induction forges are so much better at heating metal, it's not as simple as sticking a piece of stock in and hoping it heats your metal thoroughly. More energy is going into the metal than would ever really go into the metal if you were using a propane forge. This is why it's important to not only buy a GOOD induction heater, but to understand the relationship between frequency, output power, penetration, and heat. Coil size can limit the maximum potential heat output, power output can do the same, and frequency can limit the depth and level of heat achieved. A high frequency, high output setting would be best for melting steel, while a lower frequency/ variable power output ratio would be best for forging. The big point is that it's cheaper, and more efficient in the long run to use this method; while also being faster. Time is money, money is money, and lost energy is money. You can forge hundreds of items in the time it would normally take you to forge tens, nails and leafs; knives, etc. It's even possible to forge weld with induction coils.

[@dwalachn]

it's nice of you this tour idea. Sharing your online audience to showcase others. This is nice. I think you being a nice, decent, passionate human being was one of the things that drew me to your channel in the first place althought i have nothing to do with smithing. Its lovely to see that even if you as much of a business man as you are a blacksmith now, this very humane, sharing, caring side still is what drives this channel :) Lots of love to you and the Steele family, personal and or professional !

[@dwalachn]

Damn i can't believe it's been 4 years since I subscribed to this channel XD

[@gordon3152]

Nice to see videos on how to make castings. I'm a Patternmaker and have worked in foundries for 35 years. Keep up the good work.

[@keiphillips7648]

3 Steele Videos in 24 hours!!!!!! Bloody love it! Like Christmas morning, keep them coming Jamie, brilliant work as always

[@aaronbalmes1590]

Absolutely love seeing you scale in real time. Watching the evolution over the years has been both amazing, and inspiring

[@sevilnatas]

I don't know if it is new or not, but I really enjoy the less over the top presentation style. This Alex and the one that was in the Tom Scott video were fun to watch. Keep it up.

[@HomebrewHorsepower]

Awesome stuff. It's exciting watching these guys doing old school casting. This is practically forgotten these days.

[@moxbroker]

I love watching sand casting. People who are good at it turn out some amazingly detailed pieces.

[@jamesellsworth9673]

THANKS for a look behind the scenes at what makes modern heavy technology work.

[@XionSteel]

when they said that spray was to give it a better finish, they certainly werent kidding, that looks fantastic.

[@Farmer1277]

I have always loved watching metal get poured. I used to pour lead hammers for the machine shop I worked at as a tig welder. Pretty much anything metal and woodworking intrigues me.

[@pouko1]

I worked in foundry 15 years here in Finland, and its always exciting to see other foundry workers and they methods.

[@kschleic9053]

You can tell how much all these folks love their work by all the smiles on their faces as the molten metal is flowing.

[@TheLtVoss]

Jep there are only 2 kinds of people how do such a job 1. The people how need the money and don't mind hard work 2. The people how have a passion for it I kann tell to have a team made of th later kind is a incredible working experience

[@raymondoverson8715]

Way to give back. I'm sure many businesses will benefit from your reach and potential exposure. Great work.

[@megaflux7144]

this was awesome, looking forward to the tour.

[@sersp]

Yes please more workshops. I really enjoyed the last 2 episodes!

[@TheKGBtsar]

Love seeing foundry work on KZbin, I work in a foundry in western Canada and we have the same problem, need young people to be interested in metal working 💪

[@TheArbitraryActivist]

Love the evolution of the brand and channel!!

[@dmcjewagner]

Thanks for the field trip. I enjoy the variety of this channel.

[@jrnorris81]

Alex, is have to thank you for building my interest in metal working and forging in particular. I look forward to your post every time. If you every make it back to the US and Vermont in particular, I hope I can get foreknowledge so I can learn from you directly. Please keep exploring new areas or metal work that you do to inspire the rest of us.

[@piccalillipit9211]

*NONE OF THESE GUYS* go home on a night thinking "Whats the point? My job is meaningless..." FYI - a recent survey in the USA - 70% of people believe their job is utterly meaningless.

[@x_ph1l]

Amazing casting workshop! Thanks a lot for the tour!

[@dannyrobinson3480]

The tour is a cracking idea Alec, looking forward to that.

[@davidmartens6401]

So far, you do very well with the mini documentaries on workshops!! Keep them coming!

[@Leib33]

Because of your normal method of gluing together snippets of your own work, we entirely miss seeing your abilities as a presenter. You really shine presenting, from your clarity in explanation to the excitement you raise in a topic. Thank you Alec for teaching the world these topics.

[@ferroxglideh5621]

I'm very excited about your tour idea! Please say that Joey van der Steeg will be a part of your plans, as it has been too long since we have seen the both of you work together, and you are both such great personalities. Cheers!

[@ferroxglideh5621]

If you are reading this Joey van der Steeg, I hope you are doing okay, since your channel has been running silent for some time now.

[@feeterican]

I'm glad I had to learn this in high school shop class. Our assignment was to make a hacksaw from scratch and we had to make our own sand cast and pour our aluminum handle assembly. Even though it was wood shop the teacher also taught us a lot of metal work. I also made my own tool box out of sheet metal and spot weld. Shop class was freakin awesome. I spent all my free time doing projects of my own and required.

[@adnanjam]

Sounds so much fun! I wish I had that during wood shop in school.

[@DaBuild]

Casting videos are super cool to watch! Thank you for that! (Love your passion)

[@drrocketman7794]

I used to run a hobby foundry. I had that same thing happen, when I pulled up the crucible from the furnace, I wouldn't speak, and I had this focus and complete tranquility. Ironically this is the most dangerous part of the whole casting process.

[@Curiouscrazy]

Found you via Tom Scott's recent video. I am super thrilled about your tour of Europe content! Subscribed!!! Love your content and good vibes.

[@spikely]

Loving this series and excited you'll be doing more visits of foundries and similar! Hope this incredible craft continues to thrive. Looking forward to the tour next year.

[@Ryzomadman]

My grampa was a foundryman in Glasgow and when he retired he was working for a company developing casting of polymers back during the 80's

[@swimspud]

So happy there was a follow up so soon!!

[@ScottRedstone]

England created the Industrial Revolution. Seeing the foundry at work reminds me there were hundreds of similar shops across England that turned iron into steam and into the world today. Impressive.

[@stevenkaest7306]

Thanks for another peak into that great workshop! 👍👍 Hi from Australia 🇦🇺

[@potatoarms]

That cast was so nice, and they made it look simple, but that's just pure experience.

[@tyduschl5976]

Very cool, I hope we get to see this tour of different workshops. Keep up the amazing videos.

[@orangemonkeykiller]

When i was in high school I did work experience at an engineering place that did this but for huge ship propellers. It's really incredible stuff to see first hand

[@andreipendle1778]

These last two episodes were awesome. This coming tour is going to be amazing to behold!

[@RussellChapman99]

The German side of my family moved to England in late 1800's. They were art metal workers, part of the Arts and Crafts movement, good to see some in UK are still working in this field, not everybody is in service industry.

[@pjbth]

Isn't making art for no function just another service

[@RussellChapman99]

@@pjbth Arts and crafts was about making things of beauty with function. It was a response to mass production. If you check out the metal work in the Victoria and Albert Museum, you will see what I mean.

[@peterhall6656]

Good on you for show casing this fundamental industrial process that has been behind much of modern life. These guys have got it down to a fine art.

[@eastcoastcastings]

Thank You Peter

[@MonteFisto100]

I am very impressed with this huge, heavy, hard cog.

[@nolongeramused8135]

Watching the machining process for really large gears is fascinating.

[@emmahayes111]

Awesome you went back! So cool.

[@StockyDadGamer]

I love visiting different shops too. I find myself constantly looking at different industries and the way they utilize lean principles.

[@erinhames102]

Very cool idea. I can't wait to watch all the workshops you find!!

[@lucasfineschi8982]

Never seen you so happy. Amazing the love you have for all this fabrication of stuff. Keep doing this great videos, you are great!

[@mrodumbone]

i work for a company just me and the boss we are the only people in the uk who repair church bells through heating and welding its an amazing job and in newmarket so not far from norwich where you used to have a workshop :)

[@onitramt77]

Awesome video of his factory. Looking forward to your tour around europe!

[@lugattinine8451]

Thanks for showing their work.. really incredible

[@TangiersIntrigue]

One thing that came to mind, it's outside of your route but if you ever get the chance to go to Spain, you should definitely hit Toledo, it has an ancient swordmaking tradition and you can still find a few blacksmiths there that specialize on traditional swordmaking. I imagine you'd love it!

[@onesadtech]

Fantastic video! Thanks for sharing with us Alec, and East Coast Casting! 😁

[@TangiersIntrigue]

Great idea on the workshop tour Alec! Looking forward to it!

[@syxxphive126]

Nice to see another foundry. We use three of those Tinker Omega mixing arms at our foundry in Tooele Utah.

[@carlkeim6134]

Love watching your vids..I owe you a big thank you for showing me that not always being successful is OK, it helped me start carving stone which has become a very relaxing hobby.

[@AlliB2513]

This was awesome!! Would definitely love to see some glassblowing on your traveling series

[@Arkie80]

Awesome tour idea Alec. Can't wait to see it!

[@TheThirdPrice]

The size of those gears is almost comical. Amazing work Alex and incredible work ECC!

[@eastcoastcastings]

Thank You Jack

[@ThisChaoticKnight]

I know it isn't along the trip route you are plannig, but it would be amaizing if you went and talked to Albert Collins, who is the first Master Armourer in Sweden since 1781. I've had the privilige to visit his shop and it's amazing!

[@roan5250]

You should do another casting video Alec! metal casting of course

[@benjones1917]

You should see if you can get a visit to Sheffield Forgemasters, melting, casting, forging and machining at unbelievable scale. Up to about 600 tonnes in one casting, its really quite something to see

[@tidge879]

You can tell that's hard work, there's not a gut on any of those guys!

[@jeff5597]

Awesome video showcasing foundry production... you don't see many well shot and decently explained here on the KZbins

[@roddarey3306]

High School English teacher in El Paso, Texas wishing to be part of this company. Go Canaries!

[@daz41262010]

excellent walk around east coast foundry also great idea for the new series looking forward to watching it thanks for posting Alec :)

[@Uhthis]

Those guys are absolutely awesome! incredible skills to make an incredibly scaled project!

[@ducomaritiem7160]

Great idea, Alec, a workshop tour! I look forward to it.

[@mon3d-designs]

looking forward to the tour :) built my own smelter just to see if i could, and did, 3d modeled a thing, 3d printed, moulded in silica, many coates, starting with resin, finished in course sand and resin ( like lost wax) and cast in bronze, worked a treat :)

[@thomhughes9054]

Foundries must be the only places in the world where you can say sand lid and people know exactly what you're talking about

[@brettzolstick989]

Very excited for the workshop tour series

[@craigdickinson8247]

Excited for your road trip plans

[@tyrvidar]

Very cool facility, love to see these types of operations still happening in the west.

[@poofpoof9940]

Been loving these casting videos!!! Thank you forvthe education 💖💖💖

[@steair]

Very interesting video. Can't wait for the tour!

[@paulbyerlee2529]

I remember when I worked in a foundry they would cut groves in the sand they would use to sling the mould. It was crazy to see a couple of hundred kg of sand being held that way.

[@dreadwing01]

Thanks for these awesome videos. It’s a simple and practical shop.

[@gazebodp]

Super excited for this series!

[@joe90iow]

I can’t believe your tour would not include Sheffield. The Steel City! The invention birthplace of crucible steel and stainless steel and home to the Bessemer converter. Forgemasters would be an epic site to see in a video. They are making some of the biggest castings in history up to 320t.

[@cadechristopher6456]

Wow. This is Mike Rowe level hosting. I hope this is one direction you go professionally in the future. Amazing.

[@cadechristopher6456]

Also, elegant filming. It really is an art form all it's own.

[@johannlefering3345]

Awesome idea, I can't wait for your tour of the european workshops !

[@derekcrowe3999]

Really interesting, great filming and presentation. Looking forward to more like this.

[@Larry-325]

Alec awesome idea to tour shops! Real interesting love this !Thanks! 👍👍👍

[@stefan514]

That's a very impressive cog. Congrats and thank you for showing us your huge cog