ALUMINUM DOOR HANDLE FOR HAMMERBLOW MINING MUSEUM

This is a step by step process that involves modifying an existing casting to use as an actual pattern.
Also in this video are some of the future patterns that will be used to produce production work in the next several months.
#windyhillfoundry #mississippi #aluminum #moldmaking

[@paulsilva3346]

WOW, a year already, and I enjoyed this as much this as the first time.! Although you sound more relaxed in the older vids... Thanks Clark.!

[@martineastburn3679]

I love you using Durman's wood filler - Dad and I (boy) put in in screw holes on shelves to cover the holes for paint. What memories !!! Thanks. [ Early 50's ]

[@davidc6510]

A blast from the past. These older videos are as enjoyable as the first. I did note that the sand in these videos was brown whereas more green-black in the newer ones. I also saw some titles that talked about green sand. I suppose you switched to a better media for casting. Thanks for sharing Clarke.

[@johnmanning4577]

I really appreciate how you reveal the fine points behind what I thought was a pretty straight-forward and simple process before enjoying your videos. You demonstrate the ultimate skills behind an ancient process. We all stand on the shoulders of those who have gone before and you make me realize and appreciate that to a greater degree.

[@jessejohnson159]

NICE! Bravo on the good work!

[@samuraidriver4x4]

Nice to see an aluminum pour. Dollar is growing nicely.

[@windyhillfoundry5940]

And she eats like a starved horse🐎

[@OldIronShops]

All the good stuff is at the end love the vintage pattern

[@richardhead8264]

_Beautiful lever!_ _By the way, I enjoy watching the grinding and clean-up phase._ 👍🏼

[@steveshoemaker6347]

Thanks Clark it's always....Super fun to watch you cast stuff...l really enjoy it very much....!

[@55ATA3]

Very nice pour, parts turned out looking very nice. Glad to see Dollar is looking happy and hungry, always a good sign.

[@DavoShed]

All my favourite you tubers come to you :)

[@jdmccorful]

Interesting work on , I guess, the "lockout" handle. Alot of preparation for this project. dollar looks fit and is growing. Hope she learned her lesson with wild critters.Your work schedule for foundry looks adventurous. Thanks for the update.

[@merouanemegdad8041]

your job is very goooooooooooooood

[@Machine_NZ]

Another great video Clarke. That handle certainly took some thought for casting. Regards Kevin

[@leeroyholloway4277]

Wow, I have that exact fire pot (or duck's nest) in my forge. It was my great grandfather's. I need to do a braze repair on the ash dump. Imagine my delight upon seeing that pattern.

[@windyhillfoundry5940]

It would be interesting to know how old yours is. Please sends pics to my email and I'll include your pot and history when I do the video for this. [e-mail]

[@dankolar6066]

Thanks for sharing. Like the dog bowl. It has style. Wish you well.

[@metalmogul4691]

Hey this was really interesting to watch. Thanks for doing the video and sharing it on KZbin.

[@mikemarriam]

Great video. Can't wait to see you cast that forge part. Really enjoy the collaborations you enter into also. Thanks for taking the time to make these videos. I'll probably never cast a part but I enjoy learning from what you do.

[@RRINTHESHOP]

Lots of great projects Clarke. The handle came out well and will work.

[@windyhillfoundry5940]

Thanks Randy, hopefully the other projects will crank up soon.

[@forrestsecord7743]

Wonderful, wish you great success in your coming endeavors

[@tedsykora1858]

It is great to see the vice patterns from mrpete being used again.

[@wmose3694]

i am think that is a "Champion Blower Forge WhirlWind Blast Fire Pot" they are a real treat to work with though replacing the clinker breaker is quite a pain vs firepots with a single larger hole for the air to come up through with a clinker breaker that sits in the middle

[@thomasutley]

This was my first time seeing a “false” drag. Very informative!

[@windyhillfoundry5940]

Tom, great to hear from you. I have another video coming soon that also uses the false drag👍

[@JulianMakes]

A really lovely casting! Awww lovely dog too, looking forward to her bowl casting! I really enjoyed the video Subscribed thanks from the uk o/

[@Preso58]

Dollar's gonna need a bigger bowl! Sorry, Jaws reference there. That's a very cool old pattern. I went to a bar in Cambridge, England that was decorated in old industrial paraphernalia. The walls were hung with dozens of old patterns, some quite large. They are an art form in their own right.

[@leonh67]

👍👍👍👍 I have a new Museum Of London full tour video Check out my new travel Vlog channel, please Thanks 😊

[@windyhillfoundry5940]

Mark I totally agree, anytime I get an opportunity to study patterns I'm always captivated

[@geofflewis4815]

Hello Clarke, another very interesting video. It just goes to show the time and preparation you have to put in for a "One Off project". Hope you have many more projects in Alloy. Don't know what you are feeding "Dollar" on but she looks a Million Dollars, that coat shine, is fantastic. Best wishes, Geoff Lewis, Wales, UK, 🏴󠁧󠁢󠁷󠁬󠁳󠁿🏴󠁧󠁢󠁷󠁬󠁳󠁿🏴󠁧󠁢󠁷󠁬󠁳󠁿

[@leonh67]

👍👍👍👍 I have a new Museum Of London full tour video Check out my new travel Vlog channel, please Thanks 😊

[@windyhillfoundry5940]

Thanks Geoff, I feed her basic dogfood but she also feeds on unfortunate critters around the property

[@longcaster]

Pretty work

[@ralphmourik]

Nice job on the handle! I'm glad I found you! I am new to metal casting, this looks like a place I can learn a lot, I subscribed and hit the bell, I'll be watching you 👍👊

[@glennstasse5698]

It seems clear to us ignorant ones that a handheld mechanical tamper would be a nice addition. I assume such a thing exists. But since you don’t use one it makes me think there’s a “feel” to ramming the sand that you use to gauge what’s happening in the mold. Yet more experience-based knowledge in an area full of it. BTW, Dollar is the shiniest dog in the South!

[@windyhillfoundry5940]

Glenn I have a pneumatic rammer but for this size mold hand ramming is the preferred way. I have a sqeeze Jolt that I will be cranking up for production runs soon

[@leroyc179]

Looks like dollar enjoys her food and is quickly out growing her bowl!!

[@thompsonjerry3412]

Pretty dog!

[@killerkane1957]

I figure if I look hard enough, I can find something that needs to be cast. You are GOOD.

[@windyhillfoundry5940]

Thank you👍

[@sandrammer]

Glad to see that you rammed up the riser close to the area that was to be fed. Many think that they have to make an in gate between the mold cavity and the riser when the opposite is true. Ram up the riser close enough that there is no chance that the in gate will freeze up and keep the riser from doing it's job but far enough away from the mold cavity that you will have no problem seeing where the riser needs to be parted from the casting. In addition, the rule for risers is (if you need to use one) to make sure that the riser is fed last so that it will easily feed the mold cavity while the casting is solidifying. The hottest metal must be in the riser while the casting is solidifying so that the molten metal in the riser will be drawn into the casting. If you don't, the riser will pull molten metal into itself from what ever source is nearby so that the riser will have no shrinks. That would likely be your casting. Enjoying your work and looking forward to you casting the firebox whose pattern looks to have been made in the '30s.

[@leonh67]

👍👍👍👍 I have a new Museum Of London full tour video Check out my new travel Vlog channel, please Thanks 😊

[@windyhillfoundry5940]

Thanks Sandrammer and yes I always try to hug the mold cavity at the thickest section when risering. I have been fortunate not to experience reverse flow but I know that can happen

[@larryernst6349]

Thx for the detailed explanation about the different sand, sounds like you know what you are LOL

[@MoondyneJoe]

Hi Clarke, I noticed Keith Rucker did a very informative video recently on pattern making for those who don't realize just what is involved in the process

[@tropifiori]

I am a hobby blacksmith. That is a cool looking fire pot. You will have fun with that. Nice video Frank

[@leonh67]

👍👍👍👍 I have a new Museum Of London full tour video Check out my new travel Vlog channel, please Thanks 😊

[@windyhillfoundry5940]

Thanks Frank👍

[@donniebrown2896]

Your work is quickly gaining acknowledgement. Have been seeing you mentioned in other channels quite a bit. Mainly in the castings of old construction equipment where replacement parts are not available. When you talk about how much Dollar eats it reminds me of our black lab we had. High energy needs lots of fuel. Be safe and thanks.

[@windyhillfoundry5940]

And she's packed with energy😁

[@geofflewis4815]

Hello Clarke, my daughter has a short coat golden Labrador-- Oskar, 3 years old, he eats his food as though he has never been feed before, he is a rescue dog his previous owner gave him to my daughter at 8 months old, just lost interest in him. Now he is fantastic, and so happy. Best wishes, Geoff Lewis, Wales, UK, 🏴󠁧󠁢󠁷󠁬󠁳󠁿🏴󠁧󠁢󠁷󠁬󠁳󠁿🏴󠁧󠁢󠁷󠁬󠁳󠁿

[@donniebrown2896]

@@geofflewis4815 Geoff, there is something about any breed of lab that can't be explained. After our black lab disappeared I swore to never have another dog. That was until my wife gave me a rescue blue heeler (ACD). He's now 4-5 years old and by far the smartest dog we've ever had. Took him a while to train US but we are coming along. Not a day goes by I don't think about what y'all are going through in the UK. Be safe mate.

[@What2Melt_by_Randall]

Nice vid.

[@windyhillfoundry5940]

Thanks👍

[@jerrycoleman2610]

Clarke, Awesome video, great content, really enjoyed watching and thanks for sharing your video, hope you also have a great day.!.!.!.

[@windyhillfoundry5940]

Thanks Jerry👍

[@TomChame]

Very neat nice job, thanks.

[@leonh67]

👍👍👍👍 I have a new Museum Of London full tour video Check out my new travel Vlog channel, please Thanks 😊

[@WayneT51]

G'day sir, greeting from down under 🇦🇺. I really enjoy your videos with the explanation of the process (yes I also follow Keith 😉) FYI my good lady was born in Tupelo and grew up in Jackson so I don't need subtitles too understand y'all) 😉😁 Keep safe.👍

[@windyhillfoundry5940]

My wife is from Iowa and I understand very little that comes out of her mouth so you are doing great👍. I am taking on some work out of Tupelo by the way and work during the day time in Jackson at what used to be called Vickers, I'm sure she has heard of it

[@Toolman22364]

Pretty cool stuff Mr Clark .👍👍🇺🇸🇺🇸

[@windyhillfoundry5940]

Thanks Bill and hope you are fully recovered now👍

[@Toolman22364]

Windy Hill Foundry not yet still in the works . PT for 5 weeks.

[@dicksargent3582]

Your fire pot pattern is for a champion blower and forge co. whirlwind 400 forge. If you really want your forge to work properly with that pot you'll need to get the matching tuyere and clinker breaker to make castings from. Unlike most other fire pots this champion pot requires it's own specific tuyere /ash dump and clinker breaker.

[@windyhillfoundry5940]

Thanks for the info👍

[@calvinjutila8270]

Lookin' good.

[@leonh67]

👍👍👍👍 I have a new Museum Of London full tour video Check out my new travel Vlog channel, please Thanks 😊

[@larrycherrington7338]

Very interesting. Thanks

[@leonh67]

👍👍👍👍 I have a new Museum Of London full tour video Check out my new travel Vlog channel, please Thanks 😊

[@danbreyfogle8486]

Dollar didn't stay a small pup very long. Great video

[@windyhillfoundry5940]

I'll just be happy when she grows out of her puppy stage.

[@waynep343]

you can probably build a big belt sander using a piece of rectangular tubing and a pair of automotive hub assemblies .. using half CV shaft to drive one end directly coupled to the motor and the CV shaft sticking thru the splined hub and bearing assembly. . only issue would be finding belts that you can use over the tires with wheels that will bolt to the hub..

[@windyhillfoundry5940]

Thanks Wayne, that's a great idea and is something I would probably try. Finding the time to build it is my biggest challenge

[@wi11y1960]

Looks like the handle for a walkin freezer type door.

[@georgehill6569]

Dollar is a very pretty dog

[@nashguy207]

Thanks for sharing Clark. Looks like a lot of cool projects you have coming up. Give dollar a hug and belly rub for me. God Bless!

[@kristianneef828]

00

[@EmmaRitson]

busy busy busy... wow.

[@leonh67]

👍👍👍👍 I have a new Museum Of London full tour video Check out my new travel Vlog channel, please Thanks 😊

[@windyhillfoundry5940]

Emma I'm only showing the tip of the iceberg here🤣

[@WreckDiver99]

Looks like you've got a good problem to have there! I do have to ask...was it from Keith Rucker that got all these guys heading your way? Keith has been using you for quite some time, but it seems just recently everybody has been hitting you up. Good for you!!

[@windyhillfoundry5940]

I would have to say yes. Keith and Adam have had a large part to play in getting my name out there.

[@WreckDiver99]

@@windyhillfoundry5940 I found you via Keith, and I saw Sand Rammer sent you some stuff too. I'll say, Sandrammer is like watching a college professor...HOLY WAH! SO MUCH INFORMATION! LOL Thanks that that Video from Adam, I found Cast Iron Gypsy, and she's really amazing, some really cool and intricate work. Wish I had the hands, patience and eyes for it...getting too old. LOL

[@sandrammer]

@@WreckDiver99 , thanks for the complement WreckDiver99! You should see how much information I edit out to keep the time of the video down. lol

[@jayreiter268]

Clarke hope your have your helpers lined up. That level of production looks like a five man job..

[@windyhillfoundry5940]

Jay good help is really hard to find here😞

[@donniebrown2896]

@@windyhillfoundry5940 wish you were closer, I would volunteer. Best I can estimate I'm about 3 hours east of you.

[@windyhillfoundry5940]

@@donniebrown2896 thanks Donnie, I appreciate the thought. I will pull these off just not at lightening speed

[@shanek6582]

Holy sh!t I would love to buy one of those ducks nests blacksmith fire pot! Are you planning on selling them? Thanks. Mine is made out of 3/8” hastelloy from work so it’s going to last a few thousand more years lol but I’d love to have something you’ve made..

[@windyhillfoundry5940]

Thanks Shane, I won't be selling these but Andrew Alexander owns the pattern. He may be interested in selling castings from it. I will need to be careful with this as I mold not to damage it, with that said I'm not sure because of its age how well it would hold up to many uses

[@roosterman8911]

On your small logos, what do you use as a separator so the sand will retain its shape and detail ? Im a newbie and im having trouble getting my small letters to maintain their shape

[@windyhillfoundry5940]

I'm not sure I'm following you but if you are talking about deep pockets in letter like ABR etc, I fill the background often with paint to minimize defects

[@Daniel_lebieR]

On how much psi/bar do you have your kompressor set? With my casts (garage projects) I was always a bit hesitant to use one... but I was having problems with fine sand from the edges from time to time.

[@windyhillfoundry5940]

I have no idea what the pressure is set at because these cheap regulators seem to have a tolerance of +/-10 psi. I adjust my pressure to a point it doesn't tear mold faces up at 1 ft away

[@TheJohndeere466]

Did you ever try using pure clay to make your false drag

[@oneshotme]

That bowl looked more like for my Chihuahuas than your dog lol Chihuahuas than your big dog lol Enjoyed your video and I gave it a Thumbs Up

[@windyhillfoundry5940]

Thanks Oneshot👍

[@oneshotme]

@@windyhillfoundry5940 You're welcome

[@mikenixon9164]

Didn't mention your squares ? Good video.

[@windyhillfoundry5940]

True, that will be brought up soon along with the angle blocks👍

[@SandBoxJohn]

Have you considered doing the straight edge casting from a match plate?

[@leonh67]

👍👍👍👍 I have a new Museum Of London full tour video Check out my new travel Vlog channel, please Thanks 😊

[@windyhillfoundry5940]

Yes and the 12" is going to be on a plate

[@SandBoxJohn]

@@windyhillfoundry5940 Cool ! My father produced the match plates for many of the item from Originals by Cambron. Most of the plates rendered six brass castings.

[@domdipyatic3997]

Interesting as usual Clarke. Since you mentioned the lip of your crucible wearing down, I was wondering if you buy your crucibles or make them? I’ve watched KZbin videos of people making their own crucibles, graphite and clay. Is it worth it?

[@leonh67]

👍👍👍👍 I have a new Museum Of London full tour video Check out my new travel Vlog channel, please Thanks 😊

[@windyhillfoundry5940]

Dom I buy certified crucibles. I have studied making those years ago and if all I were to pour would be aluminum, I may have pursued it but not with iron temps.

[@capman911]

Will the straight edges have a level on them?

[@windyhillfoundry5940]

No Mark but I have cast iron levels in mind one day

[@garethanderson4084]

Re: logo problem. Although maby adding complexity. Is it possible to co2 cure a small cap of sand to include in the flask? I'm probably preaching to the choir here lol. ✌️

[@windyhillfoundry5940]

Yes I've thought about that. I'm trying to keep molding tricks to a minumum to keep the price descent

[@TheOmegaFleet]

For less experienced casters, would it have been easier to drill the hole and chamfer it after pouring?

[@windyhillfoundry5940]

That's what he will have to do. These didnt make it through

[@johnnicol8598]

Wouldn't it be way easier to fill all that in with Bondo? I'm guessing Durhams is water glass (sodium silicate)?

[@windyhillfoundry5940]

I've used bondo and it's a little more than I want to deal with. I seem to never get it to mix right and it always hardens seconds before I get a chance to apply it

[@rufusmedrano2962]

Are you able to use the sand multiple times?

[@windyhillfoundry5940]

Yes, I know a college that is still using the same same that was purchased in the 1950s. They do mostly lower temp alloys though

[@RowdyVnson]

Brrrrrtt

[@henrikstenlund5385]

Thanks for sharing. This is most interesting. Btw, I made a traveling water bowl for my dog of 3D plastic and it works perfectly. I made the design in 3D and then printed it out in ABS having such a form that it does not splash water while it is in the car while driving. I might make that a product available for all. Casting it in metal may be a bit complicated.

[@windyhillfoundry5940]

If it has a lip on the inside it would require a core for sure

[@henrikstenlund5385]

@@windyhillfoundry5940 I have no experience in these. Do you have a video in which you an example?

[@kevinmcenhill2656]

What is the difference between a master and production pattern?

[@windyhillfoundry5940]

A master is used seldom to produce production patterns to minimize wear on the original

[@percival23]

This would have been a lot easier on a CNC Machine. You would just have to take 5 tries and 23 hrs to make the special CNC holder for this piece. And then just 6 tries and 19 hrs to make the final piece.

[@windyhillfoundry5940]

Hi, as a former machinist I don't beleive I was ever able to buy a billet to machine down and come out ahead of casting one but things may be different these days. Regardless, if the customer prefers to have it cast that's his decision not mine

[@larryernst6349]

Just curious, why are you using different sand for aluminum?

[@ChirpysTinkerings]

The red sand is petrobond, it's an oil bonded clay that's designed to give good surface finishes on lower temp metals like aluminum, brass, bronzes, etc. The iron would burn the oil and binders out of petrobond, so you have to use greensand with coal dust in it, which helps keep the iron from sticking to it and can handle the heat.

[@windyhillfoundry5940]

This is ideal for non ferrous material. It leaves a much better finish for making patterns

[@windyhillfoundry5940]

@@ChirpysTinkerings well said chirpy👌

[@CothranMike]

@@ChirpysTinkerings coal dust no matter how fine is not the only thing you can add, any form of graphite will work great but coal dust works best -but does anthracite coal dust work as well, does the degree of hardness of this additive group matter, fex [just random thinking but if the refractory/release agent in the clay wasn't graphite what could it be what form would it take, iow, what else works and for what application]

[@ChirpysTinkerings]

@@CothranMike not really, you want the volatiles from the bituminous coal, which when the metal hits it or the heat hits it, the coal burns converting to coke and off gassing which lifts the metal off of the sand, which is what keeps the metal from sticking to the sand as it's flowing into the molds and until it forms a skin of iron that keeps it from sticking to the sand. Anthracite coal just doesnt have the enough of the volatiles to work without adding a major excess of coal, which can choke up your sand in pretty short time. Graphite doesnt release any volatiles at all, so wont work for that tbh, and while you'll get a better finish, it doesnt stop the sand from sticking, and the graphite usually plugs up the spaces between the sand grains, decreasing the permeability of the sand, and you will end up with blowholes and other defects if your not very careful. I know that wood flour/fine sawdust can be used in small amounts in place of the coal, but it has it's own set of problems that you will run into, and it really decreases the green strength of the sand. It will burn, off gassing and will lift the iron up off of the sand, but like I said, it creates it's own set of problems.

[@vicferrari9380]

Are you aware of using a cutting wax such as this on your cutting disks and flap wheels? It is a miracle worker when working with aluminum. It prevents clogging and greatly increases cutting speed. Could be a good tip. Love the videos. CASTROL METAL CUTTING LUBRICANT TYPE, 15 OZ. CONTAINER SIZE STICK WAX

[@windyhillfoundry5940]

Dan thanks for the tip. I rarely have to grind aluminum but when I do I'll look into this. Thanks again👍

[@glennmoreland6457]

He'll have to make sure the missus is out before putting stuff in her oven....

[@windyhillfoundry5940]

🤣

[@honthirty_]

I will need to go see the handles on the Museum in Tucson. Dollar's bowl COULD be raised up on the feet about 4 to 6 inches. My labs eat better, higher.

[@rustysteed8414]

Agreed. I fed my St. Bernard's by putting their food bowls on a small platform about 11" high.

[@cammurray8453]

Higher? Like off the coffee table? Out of the snack bowl set out for company?

[@barryfields2964]

I thank a metal cutter bandsaw would save you a lot of time too.

[@windyhillfoundry5940]

Yes, and that may be coming sooner than later

[@MoondyneJoe]

Hi Clarke, I noticed that Keith Rucker recently put out a video on Pattern making (kzbin.info/www/bejne/h2HIloqsep2gnNU) which is a perfect accompaniment for this video, most people don't realise just what is involved with the process and how to make a pattern so the project turns out the best outcome for the part concerned, and the casting process. You just proved how much-hidden work is involved but not all of that work, Keith goes into more detail that might help people understand why what looks like a simple handle to casts can cost so much when YOU have to fill in the blanks! In you cleaning up afterwards of the part could I suggest that you might find a band saw very handy for removal of surplus materials, then use a 3 x 72-inch belt sander. The band saw would give you better control and speed up the removal of the bulk of the material where the angle grinder is clumsy in comparison and can easily slip and gouge out materials it wasn't meant to. That's just my thought anyway. Thank you for another interesting video Clarke. Tony From Western Australia.

[@windyhillfoundry5940]

Thanks Tony and yes I do need a bandsaw. I had several over the years but never when I really needed one the most. Keith helped me out a lot with that video and I plan on making one soon where I will start from scratch and cover all the obstacles

[@MoondyneJoe]

@@windyhillfoundry5940 Clarke that will be fantastic, especially from the aspect of a person who is using patterns every day you have the grasp on what YOU need to make the job as streamlined as possible, grin you may as well train the future customers now before you really get busy and by the looks of it it seems like work is going to only get busier from here out,( you seem to be getting a well deserved name for your self!) I can see you very quickly needing to hire staff to spread the workload From those I have observed like Myfordboy, Olfoundryman, and MrPete222 just to name a few in the past have done a video or two on pattern making As I said I'm looking forward to your contribution Clarke, You can never learn enough about the things you are interested in. Tony from Western Australia.

[@michaelangelo8001]

What about shrinkage?

[@windyhillfoundry5940]

Shrinkage was not a concern for the customer on this application.

[@michaelangelo8001]

@@windyhillfoundry5940 Okay.

[@philipwolf3619]

Lost wax ?

[@windyhillfoundry5940]

Not fully equipped for that yet

[@mitchellholstein3495]

P