'Casting At The Foundry' - Will my pattern work?! | Reviving History (Episode Four)

[@montedaestrada3563]

You have to love the typical small British Companies keeping tradition alive. It was such as these that made the Industrial Revolution what it was. These skills must be maintained.

[@garyhughes5461]

Amazing to see how things were done, and how they can still be done. But more it's great to see the excitement of someone with so much experience doing something new.

[@paulshipley5669]

I served my apprenticeship in an iron foundry back in the late 80's, your video took me all the away back, nothing smells like a foundry or core-shop. Thanks for sharing.

[@McElhinney65]

Most exciting series of videos I've seen in years. When I've watched The Repairshop with my parents I've remarked "This guy Dom knows his shit." Then I find you remaking Ranalah wheeling machines!

[@ballpien]

Fascinating project!!! It's neat to see a tool like this revived. I'd double check that the metal actually is lead and not babbitt bearing material though. They look similar and melt at a low temperature. Babbitt is used to make cast-in-place bearings (a cast iron pillow block is placed around the shaft and the void space is filled with molten babbitt metal), and this seems like a very similar application.

[@GARDENER42]

I'll wager it's babbitt or a similar alloy, as lead is too soft & would loosen under the pressure applied.

[@stevelucas2117]

Thank you for taking us all along to East Coast Casting. I thoroughly enjoyed watching the process! How cool would it be if you would consider putting YOUR initials 10:35 on the new nut?

[@DominicChineas]

Haha, a secret signature! Good idea

[@asciimation]

I've done simple casting at home with aluminium but haven't quite progressed to using cores yet. It's good fun but quite an investment (no pun intended) in time to get everything setup and learn how to do it. Very rewarding though. But realistically I am still just at 'Hello World' levels of experience. The trouble with hobbies is knowing when and where to put your time as if you're not doing things professionally you only get some much time to put into things. You can't explain all of it simply but you're doing a great job trying, most entertaining thank you!

[@DominicChineas]

I’d love to give it a go myself! Well done.. thanks for watching

[@danielhayton9438]

Thirty years ago, I was cameraperson when the cast iron parts for the Science Museum's build of the Babbage Difference Engine were produced at Queenhithe on the Isle of Sheppy. The SVHS camera was a shoulder mounted Panasonic which was a far cry from today's kit. The resin sand, casting boxes and the heat an sound of cast iron doesn't change! (for some jobs the foundry still used greensand)

[@adrianrevill7686]

Nice to see a working foundry. Maybe you should have made an alignment tool before melting the lead.

[@samrodian919]

Nicely explained Dom. I used to teach woodwork and metalwork back in the late seventies and eighties and used to do pattern making with the lads and riddling the green sand wetting it to the correct dampness. Making the moulds from the patterns, and casting their aluminium pieces. Great fun, don't know if the elf 'n safety gods would allow it now in high schools, I very much doubt it lol

[@someoneelse7629]

You found yorself a good foundry, that understands the importance of letting you be a part of the first pieces made, for them it's just another piece out of thousands, for you it's a baby being born, and they let you own the moment. When you cast a desktop scale-model for rolling buisnesscards, I will buy one, and a t-shirt, just to support you. I can re melt the babbit (lead) for you

[@nickduffy8482]

That was so interesting Dom. Everything today is electronic or robotic and that is part of the reason we have become such a ‘throw away’ society. These old machines are made with simple and basic components and can be repaired and upgraded and will last many lifetimes with the proper care. Great series, i never thought I would get so engrossed in something I’d never heard of just a few months ago.

[@rickswanson3687]

As a teenage boy I work summers in a iron foundry. I ran the sand muller which mixes the ingredients to make the sand for the moulds. From my location I could see the entire moulding process. We also had the pattern makes which was a fascinating process. Brought back some good memories. I also wear several scars from my foundry days! Enjoy you videos.

[@blacksquirrel4008]

When I was a kid I got to hang out in my grandfather’s foundry, where we made sand cast architectural features and souvenirs. It was glorious, hundreds of patterns hanging from the ceiling and a huge caldron of pot metal which was never allowed to cool.

[@neilshep50]

Takes me back over ( don't tell anyone ) fifty years. The school I went to had extensive workshops including pattern making shop, casting shop, fettling and metal working machines woodworking and latterly electronics. Each year we spent a week in one of the shops. Set me up for life. I can empathise with your delight in your first casting.

[@markdavis2475]

My old school in the 1970's had the same. QE Boy's Barnet. Wonder if they still do?!

[@neilshep50]

@@markdavis2475 My old school doesn't. They knocked down the old workshops and chemistry building and replaced with a new science building. Allegedly, the workshops were used during WW2 to make parts for Spitfires.

[@markdavis2475]

@@neilshep50 Well I guess a new Science building is better than nothing! Bit gutting though.

[@weevilinabox]

I'm always impressed how time-served moulding toolmakers and casting pattern makers seem to think so effortlessly in terms of positive and negative space, undercuts and draft angles. I design injection moulded-parts, so am very familiar with such technicalities, but when I work with guys like these, their ability to look at a finished part and "see" the tooling* is on another level. * Or vice versa, which really ties my brain in knots.

[@NSYresearch]

Yeah... what he said.... impressive

[@johntisbury]

Another great video on the series. Very interesting process with the casting and East Coast Casting, great to see and understand, well explained. We did sand casting at high school using molten aluminium back in the late 70's in our metal work class. Probably would not be allowed nowadays.

[@simondavies9924]

have just watched the salvage hunter best restorations and a metal smith in dorset mat Edley is using a Ranalah on a french copper bath repair it was a pleasure to see one in use and he was saying how they was used in ww2 as you have said before so its one more survivor to add to your list :-)

[@GARDENER42]

I hope the foundry guys are managing OK with the current insane energy costs - must be a major part of their expenditure.

[@DominicChineas]

I think they have a pretty hefty electric bill every month!

[@GARDENER42]

@@DominicChineas 380 KwH/tonne for melting cast iron, so your Ranalah alone (I see 750kg quoted elsewhere) used about as much electricity as I do in a month

[@eastcoastcastings]

Electric is a big factor for our business. We have a power factor correction unit and locked our prices until 2026 last June, so we did the right thing as to all the increased energy cost presently.

[@GARDENER42]

@@eastcoastcastings I bet you're relieved you picked exactly the right time to do that.

[@paulelliott2861]

Great film the workmanship out standing. Just the best thing on KZbin 👍👍👍👍👏👏👏👏👏👏👏 paul Wimbledon .

[@robinflagg9207]

Live couple a miles away from them casting lads , what a place to look round , that is a skill that must last for ever , All The Best with your project

[@doczoff5655]

Hoowee!! Given the expertise and labour involved I can see this project won't be cheap! But I'm not criticising here Dom, quite the contrary! I'm acknowledging and respecting your level of commitment! Be proud!!

[@DominicChineas]

Thank you! Yes I can confirm it is definitely a very expensive project, but you can’t put a price on the history wrapped up in these old machines and skills! I’m doing what I can to keep the skills alive, thank you so much for the support

[@unclefranko2452]

Crickey Dom ,that's the best video I have seen for years! How interesting, I really loved seeing your part being made . You looked so chuffed mate . Can't wait for the next one Regards Frank

[@ennisskalski719]

The forge reminded me of many episodes of How It's Made. From small productions to mass-manufacture, the main difference seems to just be levels of automation.

[@gordonagent7037]

Dom, I found myself sitting in my lounge chair watching this episode and caught myself smiling right at the end, you were like a kid in a candy store and I felt your joy at this first casting. It is going to be a hell of a machine

[@three-phase562]

Great video, that brought back some memories of my time spent as a wee sprog in a foundry. Spent most of the time digging the machines out of sand mind you!

[@sofa-lofa4241]

Great video, the foundry guys really know their stuff! I used to work for an aluminium casting company, we did sand and investment castings, I worked in the machine shop (I also did a few months in final inspection and the foundry) and my dad worked in the x-ray dept. and I also managed to get my mate a job in the dip room, This video took me right back, thanks for the memories! Love the Ranalah series, I love the way you are trying to make them as close to the originals as possible, I can't wait to see these iconic tools being sold once more... Subbed

[@DominicChineas]

Thanks for the sub! Glad you enjoyed it, yes Chris and his team really do know there stuff they are a clever bunch.. it’s nice knowing I’m in safe hands with the project

[@sofa-lofa4241]

@@DominicChineas yeah, not to mention your 3d modelling wizard🧙‍♂️ Great teams create great things

[@migalito1955]

Fabulous. It's great that you connected with Chris because it seems that some companies could get their knickers in a knot unless they have scores of parts to cast simultaneously. I had a neighbor that was a pattern maker and from having met him I am in awe of the art of the process. The interesting pattern is going to be the main body of the machine. Your spot on, that casting will be epic.

[@nicklevkouskis2885]

Usually heat the mold to eradicate any moisture and gassing of the casting This can result in micro porosity which is the brain of any foundryman. Worked with so many foundries over 40 years on so many processes but it is really great to demonstrate the pattern and molding process Well done.

[@CornishMiner]

As always, a joy to watch. Amazing to see the secrets of the machine's construction revealed when you removed the lead.

[@wsherratt5159]

Nice one Dom. This journey should make us proud that there are still skilled people at the heart of business. Let’s hope that some of the home grown talents are supported by government in an effort to keep Britain Great! Keep it going mate. Wayne

[@petewarby7158]

Not only that, hopefully all those people that have been messaging saying how you've been doing it wrong have been deleting posts to save embarrassment lol. Well done everyone involved

[@wsherratt5159]

@@petewarby7158 Here here Pete! I think it’s a brave person who puts themselves out there trying. As for those people and their comments, well, it’s better to be thought of as a fool than to open your mouth and remove all doubt!!

[@michaelgibson4705]

Do you have to be a special type of nerd to get excited about a reconstruction of a seventy year old English wheel ? If so guilty as charged, love it 😄

[@spiffer27]

Brilliant Dom! Were they able to modify your original pattern or did they have to remake it? Is that the Ranalah frame pattern behind you at 16:38? That molten lead technique is how they used to fix railings and hinge pins etc into stonework. No big deal really that you had to melt the lead to remove the inserts. You can make some installation jigs now and practice installing them for your new ones. Can't wait for the next instalment!

[@MidEngineering]

Looks like the Ranalah pattern - well spotted!

[@gedtoon6451]

I think you could be right!

[@MidEngineering]

Actually, I think it's this - kzbin.info/www/bejne/oYimdGeNfNeqg9E

[@Point221b]

Hundreds of casting experts up and down the country saying "yeah, that's how I thought they were going to do it "! 😂 Blimey those guys know their stuff 😯. Well done Dom. As you say the main casting will be epic! 🤗

[@Dug6666666]

Another pattern making expert here :) (44 yrs in the trade on both hand tools and later using CNC) I think it should be made clear that what you supplied to Chris as the foundation for a pattern did him little favors. Giving him the sample casting and saving him some work with a dimensioned drawing would be a better option. It would surprise we if he didn't start again from scratch particularly since it is now a split pattern. Option 2- It is not uncommon these days for even hobbyist to have access to CAD software and even their own CNC router. Discuss with your friendly foundry what they would like as a pattern showing them the sample casting, things like:, split line, tapers, core requirements, print location, print to core clearance, machining allowance and scale factor for contraction ie x1.01 for cast iron) go home and model it as Chris made it, and have it CNC routered. Machine your pattern in material thickness layers if you don't have the Z axis travel or cutter reach. Nice stable timbers are great for hand made patterns, it adds however an extra complication of grain direction for strength and dimensional stability when CNC cutting it and also corner chipping from the cutter. Moisture resistant MDF is a good affordable option for CNC routing patterns. Tall thin features in MDF can be a bit fragile in a foundry, but drilling down them and gluing in wooden dowel will give the necessary bracing. I appreciate Dominic's enthusiasm for bringing old school skills to this project, it should be appreciated also though that the CNC approach is a different animal and best used to its fullest completing all the finer points in CAD. (comes with a steep but interesting learning curve,that will be very satisfying). What I am describing is 3 dimensional cutting finishing with ball nose cutters, not end milling profiled shapes. Much enjoying the series, just chipping in with what I hope is helpful to the punters who might want to have a go at patterns for their own projects.

[@DominicChineas]

Thank you very much for Sharing your knowledge, please watch the rest of the ranalah series, last week we met the pattern makers working on the main frame I think you would appreciate it! Let me know what you think

[@Dug6666666]

@@DominicChineas I'm glad you took the input in the spirit it was intended. :) Yes have seen your most resent video on the main pattern (it was the first of yours Google put me on to) have since back tracked the rest in the series. They are doing a great job of the pattern, it should give you many years of use. What the engineer modeled for you in CAD with all the tapers included would make an ideal basis for CNC machining the pattern. I quite understand the value you see in having it done traditionally including leather fillets. It adds to the heritage of what you are doing bringing back an old marque. If you are interested here is a link to some of my CNC patterns (some are plugs for composite molding) www.flickr.com/photos/dugz-pix/sets/72157679680377043/

[@eastcoastcastings]

Always appreciate input & I’m always willing to learn from others with there experience 👍🏻 Rgds, Chris

[@nathancowieson511]

Well I'm not generally given to public emotional outbursts but honestly that casting process is one of the most interesting and exciting things I've ever seen. What an amazing video series, thank you Dom (and Dan).

[@DominicChineas]

I appreciate the message thank you!

[@bruceblackerby3742]

Another great video. All the forgotten technology that got us to where we are. Amazing to see the foundry casting new Jaguar 3.8 litre blocks! Gives me hope that we will see more of this retro activity in the future!

[@snooziesuzi]

That was so interesting to see how the casting process works. What a journey you are taking us all on. So exciting. 🎉

[@DominicChineas]

Thanks Suzi! Hope your well

[@andrewhawkins6454]

I'm really enjoying your series. What a fantastic journey you're on. And we're all along for the ride. Thankyou very much Dom. 🏴󠁧󠁢󠁷󠁬󠁳󠁿👍

[@Lifesgood427]

Excellent Dom

[@johng7rwf419]

Have you thought about some type of alignment jig for those parts held in position when the molten lead is poured in? The welded locking arrows, you could add 'DC' for the new generation built by you. Fantastic at the casting shop. Top man, keep up the good work... J

[@gordonagent7037]

Totally agree about the alignment tool, awesome idea and so practical. Top suggestion

[@sparkywig]

Thanks Dom. I find this Ranalah journey fascinating.

[@DominicChineas]

Thank you! I’m glad your enjoying it, I am learning a lot!

[@mikehardy7060]

Brilliant

[@peterjones3453]

What a fantastic vlog this week. Happy memories. Used to do casting when I was a DT teacher many years ago, but only with aluminium and once with brass. Used to love it and the children were always enthralled by it

[@terrywhite5240]

Well done Dom Keeping the skills of the past alive is important in this world of modernization

[@MikeSmith-sg9pt]

That was totally absorbing to watch. I love the beauty and elegance of castings from the smallest piece to the biggest. I don't know what half of the components are, but I'd just adorn my house with them 😂

[@MikeSmith-sg9pt]

Speaking of big engineering, I just saw this clip. Imaging doing a strip down and rebuild on that! facebook.com/885615018152283/posts/4104059782974441/

[@martyn6542]

Could watch this all day

[@marieeaton-smith5168]

What an education. These foundry guys are amazing. Thank you.

[@davidmanning8329]

Loving your progress of a real labour of love. So inspirational! I do hope that if there are improvements in metallurgy in the last 90 years you'll use them - Rannalah used the best materials available so you should too. Things like the lead collar that had been hit with a punch to make it sit better. If you can make the collar last longer, then go for it without guilt. Can't wait to see how it all works!

[@mfwwhelan7561]

Another fascinating episode! Mike in Germany

[@shaunhazeldine3377]

Excellent absolute great video great to see you look so happy

[@neilmackinnon3371]

Wow, that brings back memories for me, I used to deal with a foundry the same as that up in Derbyshire, they would cast finials and other decorative finishing pieces for me. I also used to deal with some large foundries in France, they could cast traditional cast iron lighting columns up to 10 m high... in one pour! Great video Dom, thanks very much.

[@NathanielStauber]

While watching another KZbinr, Keith Rucker, I remembered this video and had to come back to comment. Perhaps the lead holding the inserts is actually babbitt. The idea has inspired me to research it.

[@annemarsden2323]

Brilliant thank you for sharing your wonderful videos

[@DominicChineas]

Thank you for watching!

[@kevinisaac9139]

Very interesting Dom 👍

[@suepatrick3705]

This journey is wonderful ! best wishes!! Thanks for doing a great job showing the foundry ! My Grandfathers owned one together, never would have found out what it would have been like.

[@bozz1954]

In the early 70’s I worked at Longbridge , Austin cars as a sub contractor sheet metal worker and they cast there own parts in there foundry. Brings back memories of those days. Loving these videos Dom

[@dalepomraning299]

great video, I'm impressed with energy of that casting shop, they are really good, doing engine blocks, I wish I had casting company near me, I'm a 40 year machinist. So I see every step, yes i'd like to make a English wheel.

[@DominicChineas]

Thanks for the message! The foundry was amazing, glad your enjoying the videos thanks for watching

[@jannerkev]

Magic Dom. Thanks for sharing your Ranala journey. My Late Dad used to use one when he was a panel beater/coach builder , and always wondered where all the bits he used to use were sent when he retired . Great memories. Thanks for bringing them back to me.

[@andywarrington4738]

superb , thanks Dom

[@kevinball2517]

Nice one Dom enjoyed that

[@gavinhill4121]

Absolutely fantastic

[@DominicChineas]

Thank you! Glad your enjoying it

[@StephenBoyd21]

I remember doing a very small bit of casting whilst I was at school. Nothing compared to how impressive you video looked.

[@peterhofmann8292]

Your enthusiasm is palpable👍👍👍👍👍👍👏👏👏👏👏👏

[@timhewitt394]

Hi Dom, looks fantastic, I have a Ranalah myself, and watching your posts has made me brush off the cobwebs and get back to shaping some metal and making things. If you need to borrow a complete lower adjuster wheel to copy let me know I’m only in Canterbury. All the best, and keep up the good work. Tim Hewitt

[@DominicChineas]

Brilliant! Would you send me a message on Instagram if you have it? Thank you!

[@Crewsy]

I’m glad to be along for this journey. I’m also glad I know enough to know I don’t know very much and kept my mouth shut after the last video about why your mould master wasn’t going to work unlike the KZbin casting experts that all chimed in to provide their expertise after watching professionals do metal casting.

[@andreVE4BK]

You’re a great instructor Dom! Everything came out loud and clear! Cannot wait for the next video. Congrats on your new piece; you must be really excited with the direction your project is heading to.

[@rogerbond7811]

Thanks Dom remember going round a foundry on a careers visit with school and covering it in my apprenticeship. The use of cores takes some getting your head round. I think you have enlightened a number of people. Thanks.

[@adieaf61]

amazing. Well done.

[@andypughtube]

3D printing has made it much easier to make patterns, especially patterns with cores, loose part, core boxes etc. Probably not robust enough for production use, but for the typical (hobby) jobs that I have cast, up to half a dozen, it simplifies things enormously (if you already know CAD, at least) There is the issue that 3D print needs a lot of post-finishing to get a good enough surface finish to release properly (and to colour code the faces) and most printers don't print very large. One tip is to leave holes in the parting faces to glue wooden dowels in to for the foundry to put screws in to extract the patterns. wood screws straight in to 3DP does not work at all.

[@wellybobs4403]

I am very excited to see the main casting done!

[@paulp96275]

Dom fanbloodytastic what a foundry! jag block how great is that you’ll have no worries about a great job being done ,here’s to the making of history great 👍👨🏻‍🏭

[@chipperkeithmgb]

What a fascinating place

[@stevebosun7410]

Well done Dom, that's fantastic. Here's hoping the rest goes as smoothly. Your enthusiasm is infectious.

[@kevinsimpson7114]

Brilliant video. Great explanation of the process.👌🏻

[@TheKnacklersWorkshop]

Hello Dom, Congratulations on getting the first new piece... and well done on explaining the whole process... Thank you. Take care. Paul,,

[@contessa.adella]

I am now hooked on this tale of enthusiast restoration….Nicely presented, quite enthralling in fact.

[@DominicChineas]

Thank you! I hope you’ll watch the rest we have come along way!

[@bobingram6912]

Dom . . . like a kid on Christmas morning or in a sweet shop!!!😮 Great insight into the process and a big up to East Coast for showing us around.👍🏻

[@daz41262010]

another cool episode to watch Dom :) glad to see the first part worked out well but just a thought i thought you may of put the part in the front seat with the seat belt around it lol :)

[@DominicChineas]

Haha! I did drive home very carefully! The pattern is very precious! I may need to get a box made for it

[@Cam11010]

Very cool and fascinating stuff, dom. Love it and can't wait for the next installment.

[@DominicChineas]

Thank you, won’t be long!

[@damienpurcel7244]

That was so cool, really enjoyed that, thanks so much

[@robg3545]

Interesting vid Dominic, nicely explained. Wow that lead dropped out quickly when it hit temperature. It looked very shiny when it had cooled into your art piece so wonder if it was pure lead or was a solder of some kind ?

[@michaelmiller641]

Brilliant!

[@norriestewart4333]

Brilliant video of the casting being done. There used to be a foundry up here in Scotland where I live but it's long gone now. They used to have a little truck that went to our beach and loaded up on the fine beach sand to make their mouldings from. As a time served Blacksmith I enjoyed watching the casting process. Keep the vids coming Dom.

[@oberdiah]

Lovely stuff 👍

[@thistleman5]

I don’t think I would ever need a English wheel as I mainly work in wood. However your enthusiasm ?passion for recreating a classic piece of workshop equipment is fantastic

[@willgrime]

Hi Dom, this is a fascinating series! I’m hugely enjoying watching the process, seeing all the theories and information I’ve picked up over the years put into practical action, and teaching me a few more wrinkles in the process, but the best bit is your obvious pleasure in the process you’ve instigated. I have a Ranalah, but I need a new adjusting wheel for it, so when you get round to casting those, knock out an extra one, would you, and sell it to me? Thanks! Cheers, Will

[@DominicChineas]

Glad to hear! Thank you! The adjuster wheel is the next part to make, the drawings are already done. Keep an eye on here to see it and send me a message on Instagram if you need one, they will be completely interchangeable to the originals so you can definitely have one!

[@althomas7937]

Fantastic episode Dom (just subscribed and binged watched the series - awesome!) you should replace the welded arrows with a stylised 'D' and a 'C' after all, you own the company!

[@remcotissink]

What a fantastic project ! Not a metal worker but it is fascinating...

[@nickedney1272]

Another cracking video, great to see skilled men in action. Looking forward to future developments.

[@SteveBlethyn]

Love your excitement seeing your new baby start to come to life. Long way to go though Dom.

[@meirionevans5137]

I'm as chuffed as you, somebody's Jag engine block will have shared a casting pot with your machine part. History in cast iron, brilliant.

[@chrisflemington819]

Hi Dom That was a really interesting video. I’m sure there are many people out there who understand the process but for me I just found the whole process so interesting well done. The look on your face when the first piece came off the production line was fantastic!! I have a thought for you which is many of the people who you’re getting to help you wear Polo shirts with the name of their companies on it. Why not design an emblem, say an outline in red of a Ranalah Wheel and then the name Ranalah Ltd ( I’m not sure how the company is set up in the case of using the word Ltd or Limited or ltd? But you need to use the correct version as it’s registered at companies house. Anyway just something to consider to promote your new venture!! Maybe the ladies at the Repair Shop could be persuaded to design one for you then you could buy some polo shirts in whatever colour best suits your needs and maybe just maybe the ladies would add the Ranalah logo for you?!

[@mikebull1972]

Dom, your love and enthusiasm for this project is just wonderful to watch!

[@olrenison]

Awesome. 😊👌

[@andrewmarch7891]

Excellent! Looking forward to seeing the main frame of the Ranalah go through the same processes.

[@patrickfay1055]

Great video can’t wait for the next video

[@everestyeti]

I am really so pleased for you, everything you've done so far shows in your passion to keep these old skills alive.

[@jeep2003]

I would have made a jig that holds all the pieces so that you can lead them back in the right place. They need to be aligned right when you are done

[@DominicChineas]

That’s just what I am going to do, I have a second machine that is still complete I will use to make the jig

[@seananthonyegan3395]

Very enjoyable and informative thank course 👍