CASTING A PART FOR CLOUGH42

Hello my friends, this is a collaboration between clough42 and I for a riser block to take the place of an existing compound.
The casting in this video will need to be recast but with only minor changes to the molding process as you will see. Clough42 did an awesome job making this pattern and in an upcoming video I will show the final casting prior to shipping.
#clough42 #madeinmississippi #castiron #windyhillfoundry #casting #determination

[@Clough42]

Thanks for your help with this project! The pattern is actually resin--it's just hollow, with a lattice interior. If it were solid it would be well over a pound of resin, and I'd be skeptical I could get it fully cured to the center.

[@MikeSims70]

Been on this planet a little over 50 years and I've never seen the process of casting iron. So for me, this video was fascinating. Thank you very much. Excellent video!

[@antontaylor4530]

I appreciate that you decided to recast the part. That part is so close to perfect, yet you are professional enough to chase that last 1% for James.

[@penyllanpete]

A wonderful wise friend of mine once said " I only worked once, and I retired once. Retired is better !" Stay safe and live long.

[@kendonahve924]

I'm new here. I much regret not being here to learn long ago. Much appreciated!

[@outsidescrewball]

Enjoyed…very nice video production/discussion/demonstration….congrats on retirement

[@nashguy207]

I know what you mean I used to drive across I-55 several days a month going over to Jackson it is a rough and bumpy road. Good luck on your retirement!!

[@henrikstenlund5385]

Best of luck to your new period in life!

[@floridaflywheelersantiquee7578]

Thanks for sharing enjoyed watching

[@stevewalston7089]

First of all, nice work! Secondly, it seems to me if the Mini Mite mullers are so hard to find then it would be a perfect collaboration project to spin up again, either as a finished project or as a kit with cast components that need to be machined to complete. Certainly with the number of folks performing these activities these days they would sell. If nothing else selling plans to those on a very tight budget or wanting to do everything from scratch.

[@OuroborosArmory]

It’s so cool when two of the channels I regularly watch collaborate on a thing :)thank you

[@dlstanf2]

I’ve worked harder since retirement than I did at my job and I thought it tough at times. Hope you do get to fish a little more. God Bless for all your hard work on these vids. Not easy to get it all done.

[@martineastburn3679]

Congratulation on Retiring soon. Been there since 2005 and had an LLC til 2016. Lasted a good 10 years. 🙂

[@wendellp601]

The algorithm introduced me to @Clough42 a couple of weeks ago. James does great work.

[@noisybarinavalon]

Thanks for including the diagram, that cleared up a lot of assumptions on my end.

[@TgWags69]

One of the best tools I ever bought for the shop was a burnz o matic TS8000 Self igniting torch. My original came with a fat max map gas tank, but I've used them on propane and they work fine. I make a base for it using an upside down pvc toilet flange. You have to warm it up the first time and press the tank into it. It's the only drawback to the taller torch head is they like to fall over but the base fixes that issue.

[@Rob_65]

Hmm, retirement - that sounds nice: be like a kid again and play all day in the sandbox. O wait ... that's what you do right now 🤣 I don't know much about casting and was wondering why a 3 part mold, I must have missed the explanation while getting a cup of coffee, but it made so much sense in the end. Also the shrinkage at the bottom - I've seen things like this happening to plastic injection molded parts a lot.

[@bulletproofpepper2]

Thanks for sharing!

[@repairtech9320]

This video is a much better learning tutorial with the hiccups and explanations. Thanks

[@zvonibab]

I am sure after good night sleep cast will look like million dollar .

[@GeoffTV2]

Came here from the Clough42 video. It was great watching the casting process, thanks for posting.

[@claeswikberg8958]

"I'm so... awesome" Lol that cracked me up, i know the feeling

[@zowiefenderblast4602]

Brother, it's hard when you're a protectionist! I can't agree more. I'm not in the same business. I understand the chase for perfection. It's a chore the Lord only knows. Thanks for the videos, and knowledge to pass on!

[@Daniel_cheems]

Exciting times Clarke! Good luck with your foundry business, looks like it's going to be a boomer! Looking forward to lots of Windy Hill Foundry videos, time permitting.

[@roscoepatternworks3471]

Just watched clough42 video on making this pattern. I'm a retired patternmaker and just wanted to say a little about how you could have gotten a good casting the first time. Operating on 4 hours sleep, never good in a foundry 😉. Communication with the customer is good. The part was to be machined all around the perimeter, so no need to bottom gate. As you said at the end a single riser over the big mass would have worked better. Using a knockoff rise would make clean up easier. Side gate opposite the lettering would have worked. Not criticizing, just my observations. A redesign of the pattern could be looked at too.

[@danbreyfogle8486]

Great video. I really enjoy when you try to fool the viewer. We all know the penny needs to go head down and looking to the right! Just fooling with you Clark, I hope the next few days go well as you head to semi-retirement. As a semi-retired guy myself I can tell you that you end up with less time to get things done once the regular job is done.

[@MrPossumeyes]

Thanks, Clarke. Dollar did a nice job on that drawing, too.

[@buckw65]

That was super interesting to watch. It's nice to see that things don't always go as planned. That's so cool you posted this so we can see and learn about castings.

[@HexenzirkelZuluhed]

I love this. I would want something similar on my lathe. Can't wait to see the final cast.

[@perlguiman]

I love your process. Very cool craft.

[@miken3260]

The spoiled casting would make a great base for a lamp or work light.

[@phoolb7326]

Followed you from James channel and congratulations on your retirement as I will be doing the same on about the same day. Looking forward to watching more of your videos in the future.

[@mattym8]

Cool, I just watched the Clough video! Great timing.

[@johnkey1682]

Congratulations!!!!

[@JohnK8]

This is great. I remember sand casting in metal shop back in Jr High. Back when schools actually taught stuff.

[@Blue2swing]

Haha, The penny joke cracked me up 😄. Thanks for the laugh.

[@uther10]

Congrats on the semiretirement!

[@CraigLYoung]

Thanks for sharing 👍 and congratulations on retirement

[@mikenixon9164]

Hope everything works out for you. Good video.

[@mattthescrapwhisperer]

Snakes: It's monsoon season here in Arizona, and though I have been mowing like crazy, I can't keep up and the grass is tall in many areas. I'm constantly on the lookout for rattlers; especially the Mojaves. They are the nastiest snakes in our area. What a great score on the second muller!

[@RRINTHESHOP]

Nice, congrats Clarke.

[@dankolar6066]

Retired 15 years ago. Not sure where I ever found time to work. There has never been any shortage of things to do. Life is an adventure that no one survives. Wish you well.

[@bcbloc02]

Happy retirement!! Now you can get to work!!

[@WCollinsWhiteIII]

Looking forward to seeing more of your videos

[@InssiAjaton]

Brought up memories about my first summer job, other than on our farm. There had been dust at the receiving end of hay and straw, but the black from the foundry operation was something else. It took at least two months for the carbon dust to disappear from all my skin pores. I mean it was everywhere!

[@AcidVFR400R]

here from clough42 video loving your work

[@kimber1958]

THANKS, AND CONGRADS

[@gwharton68]

Hope you can enjoy your retirement. Now the real work begins. Best of luck on your future endeavors,

[@billdoodson4232]

Haa haa haaaa! "Lets make sure theres no snakes". Not a problem we have in the UK.

[@mongo6043]

Man, I love these colab vids! Congrat's on the semi retire! Now get back to work! ; ) subbed

[@zowiefenderblast4602]

Happy birthday Mr. Pete

[@ohhpaul7364]

Congratulations on your retirement, Clark. Hope you enjoy working in your new venture with more time to dedicate to it.

[@dickmorris6310]

Clough mentioned in his video that he put a fillet on the bottom to reduce iron chilling at the sharp edge. A good concept, but with the one piece pattern it just results in the edge breaking away. Otherwise, a nice pattern. I'm surprised the lettering pulled so cleanly since it was on an angled surface. He must have put some extra draft on the letters. Congratulations on the retirement. I've often said that when I was working it thought I enjoyed my job. When I retired I found that I hadn't really liked it after all.

[@Valery_1954]

It is very interesting how this epic will end. Difficult job, many hidden nuances to consider 🙂

[@chrisj4570g]

Very neat! I watch Clough’s video and came right here to see it cast. I don’t know much about casting other than bullets, but one question: how come you poured the excess iron on the ground instead of an ingot mold?

[@crystaldragon141]

He pours so much that it's just as easy to pick up the iron flakes on the ground as it would be to cast an ingot. In fact it would probably take longer plus as he said the crucible wasn't set in the ring properly.

[@JasperJanssen]

@@crystaldragon141 besides, like, it’s iron. Not exactly the most expensive metal, so if you lose a few bits… *shrug*.

[@josecarlospoggian149]

👏👏👏👏👏👏👏👏👏

[@tiredoldmechanic1791]

Clough spent some time sanding and painting that pattern to make it come out of the mold but it also made your dust slide off easily too.

[@cmleoj]

Congratulations on your retirement. Take care of yourself and your family.

[@tobhomott]

nice pattern, off to find the patternmaking video! Good luck with attempt #2, soon you'll be able to get a full night's sleep once you get yourself down to just 1 full time job 😃

[@jamesrozell6467]

kzbin.info/www/bejne/o4WniJ-Oh76krdE

[@DavidKutzler]

6:20 Those little "avalanches" are a perfect example of the mathematics of "Chaos Theory" in action.

[@davidgreen4356]

🙆🏻‍♂️Congratulations Clarke 🍻on your new Day Job 👨🏻‍🔧

[@mumblbeebee6546]

I know you were being sarcastic but … you _are_ awesome! You still make it work, and make it work good, even when tired and the tools let you down! And if it’s not good enough, you make another one!

[@TheUncleRuckus]

Came here from Clough42 liked & subbed 👍👍 Hey for that the first casting you should turn it into something, like a lamp base or a pedestal for one of those complaint department grenades.

[@the4thj]

I am new to the channel but not anymore. It was still a marvel to me.

[@ImpactWench]

Yeah, it's best to try again on that one.

[@markschweter6371]

"I forgot the risers... I'm awesome!" 😆

[@zeke7237]

Congratulations on your retirement!

[@tonyray91]

If you found the lettering difficult it must be nigh on impossible for most of us so I would like to see how it’s done. As usual I leaned that F360 can do things that I was unaware existed. Looking forward to seeing the next stage.

[@Clough42]

It's super fiddly because there are so many boundary conditions that break the chamfer and taper algorithms against curved surfaces.

[@danieldunham9978]

Happy retirement!

[@Preso58]

Wishing you all the best for your (semi) retirement Clarke. I'm curious as to why you cut the keys in the bottom mould. Would the alignment pins in the flask not be enough?

[@brucefaz55]

congratulation on your retirement. I retired 8/2/18 and never looked back. Hard. to believe its been 4 years i. know you are going to enjoy !

[@rogertaylor1589]

Just wondering why the crucible contents left from the pour are spilled on the floor instead of a ingot mold.

[@Farm_fab]

Clark, I commented on a video made in India when they were casting the axle hubs for a Fiat tractor. They had some very good molds for these, and they cast them from steel, and I couldn't believe the negative comments about cast 7 and only 5 will work. most assumed that the hubs were cast iron. I explained that when you start with steel, the casting will be steel. Finally a few realized their mistake.

[@eliduttman315]

Those folks may have confused what happens when you remelt ductile iron scrap and cast it using traditional methods. That sequence yields gray iron.

[@llapmsp]

Good luck in retirement, I am retired and loving it. Stay safe.

[@Disneymkvii]

Congrats on your retirement!

[@ozz5350]

👍👏👏👏

[@repalmore]

I have no idea if this would be worth your time to do but make cast iron cups so your extra could be poured in the cast iron cups and the entire cup in for the next pore. Could make up sets of 4 and not cut the runners till after you fill the cups up but that's more work than picking it up off the floor.

[@mdouglaswray]

Congrats on your retirement! Now you can work hard on YOUR projects!

[@Digital-Dan]

Check out one of the newer plasma lighters. Some have a flexible neck. Light ever time, and recharge over USB.

[@marty0715yt]

Fuse?? I thought that is where the quarter goes.

[@chucksmalfus9623]

Quarter? When I was a kid it was penny, you could buy a pack of 30A fuses for that quarter

[@edwardrieve6268]

Burnt down house only cost me a penny.

[@sammorgan31]

You're in Mississippi? No wonder I can understand you!

[@windyhillfoundry5940]

🤣

[@mdouglaswray]

Some rare earth magnets in the output chute of the muller might catch some of the metal bits?

[@OuroborosArmory]

Why do you dump it on the ground instead of casting ingots with it?

[@davidapp3730]

Nice light show as you poured that one. Can you remelt the iron you dump out on the ground?

[@TheDestroyer1250]

Looks like a bit of porousity on the surface? Is that from excess moisture in the sand?

[@michaelc.3812]

Clark, has anyone ever tried to use a press to pack that sand? It does seem overly-difficult as far as packing goes, so I’m sure there are many other methods.

[@trialnterror]

Do you do aluminum castings? I have a elipse that makes a 90* then goes to a 3.5” pipe . It’s for a 98 firebird. I have it designed in fusion 360 and have printed them out! Curious if you do this type of work that’d be reasonable priced.

[@noahkatz9616]

@Windy Hill Foundry I want to do the same for my lathe; what were the labor hours and materials cost for this casting job?

[@martynbuzzing3327]

With semi retirement you should be able get a good night's sleep and do your job better with no tired issues. Good luck

[@markcrotty5094]

Congrats on the retirement

[@thomaswhaley4024]

why was the casting surface so granular WHF?

[@tacticalrabbit308]

Are you retiring? If not what would a block of cast iron cost that's like the one you are casting in this video but with a flat surface where your logo is located you can put it somewhere on there though just need a way of clamping it to a table with c clamps.

[@medienmond]

Can the castings have also more finer details? What does a casting like this cost?

[@stxrynn]

I'm glad you can go on your own terms. You may look forward to four hours of sleep AFTER you "retire"!!

[@LimeyGuru]

Are these going to be available to buy? I have the same lathe as James and I have wanted a solid toolpost for some time.

[@p.t.anderson1593]

I would recommend asking James. Typical business agreements would usually prevent a supplier, in this case the foundry, from selling a clients product.

[@Clough42]

@@p.t.anderson1593 If there's demand, I'd be interested in making something like this happen.

[@p.t.anderson1593]

@LimeyGuru - Looks like James is interested in making this happen. You should contact him...

[@Farm_fab]

Clark, congratulations on your retirement.

[@CatNolara]

What is the reason of all the little bubbles in the surface? Isn't there a way to avoid those? Also I think it would be better to put the pipe for feeders/risers in while filling in the sand, that way you don't have to push anything out of the way and damage the surface of the casting cavity.

[@pieterveenders9793]

Yes, there are ways to reduce or even completely avoid the bubbles. For one you can do vacuum casting, which will help to fill out the mold much better, or you can do diecasting (where a hydraulic piston injects the molten metal into the mold under high pressure, which produces a much denser casting and prevents any bubbles).

[@GlassImpressions]

Wouldn’t 3D machining a chunk of cast be easier?? No machining experience here so I’m curious.

[@Corvus.2606]

clough42 addresses that in his video. yes, it could be machined, but the material cost would be much higher and you machine half of it off to get the final part, with cast its already close to final dimensions.

[@GlassImpressions]

@@Corvus.2606 thank you for your reply! I’m learning!

[@codebeat4192]

Now I know why making a mold is so expensive.

[@oldschool1993]

There's an old saying - " The dream is always better than the reality" I hope your decision works out, just moderate your mind and realize that now you are going to a job which pays the bills etc. and you are dreaming of getting home to do your foundry work. Next week, the foundry will be your job which must pay the bills and will no longer be the hobby you dream of going to.