Making a 100kg Steel Anvil - The Drag and Cores using K-CAST Sand

#metalcasting #kcast #metallurgy
Welcome to our first ever video on youtube! This is the first in a short series where we will make an anvil from steel.
We are a small boutique foundry based in NSW, Australia. We have over 30 years experience and a successful business casting a variety of custom jobs. We use an electric induction furnace and melt and alloy a variety of metals.
In this first video we are using flaskless moulds made with K-Cast sand and super finish paint. We talk you through the process including making cores and dipping.
We hope you enjoy it. Stay tuned to follow the process and please leave a like and subscribe to see future videos

[@felixaubert2550]

I like the part when he doesn’t make a 100kg steel Anvil.

[@rcchristian2]

Yeah WTF??

[@Match2100]

It's almost as if it's a multi-part video or something

[@howstuffworks671]

Crikey mate....97kg....100kg....if that's all you can cry about...I think you gotta find better things to do with your life.

[@ajhproductions2347]

@@Match2100 yeah but it doesn’t say part 1 or part 2 so I want a refund

[@wfemp_4730]

@@Match2100 It's almost as if the video title was poorly written.

[@ChuckUnderFire]

I thinking this is probably the first time I’ve seen someone say “take you time, make sure you don’t take too much off” and then ACTUALLY take time, check the fit a bunch. Good on you guys.

[@ponkkaa]

It's nice to see that people care about the quality of their product and the quality of their workmanship. Cheers from New York.

[@AusMetalCasting]

He really does. Bob is passionate about what he does and Jamie has been working beside him on weekends since he was a boy. Thanks for the support!

[@tuloko16]

Remember when americans used to do things like this...now we are too lazy to do anything and just buy crap from china. Keep up the good work, and get the young ones involved on “hands on” crafts. Keep them away from their cellphones and social media. It killed America. Would hate to see Australia go the same route!!

[@TlD-dg6ug]

Nothing to see here people, just a man living his childhood dream of playing in a sandbox and making stuff. 😁

[@williampaylorjr9481]

It's good to hear from people that love what they do and even better when they can work with family which has its own set of challenges. You don't hear too much these days about preserving trades and skills being lost to large industrial companies. When my son finished high school he told me he wasn't going on to college but rather a trade school. He said he wanted to work with his hands as a welder. Just like my father and grandfather told me....take pride in whatever you do there's nothing wrong working with your hands if you're doing what you love.

[@richyearle007]

Nice work fellas.Looking forward to seeing the finished product.

[@AusMetalCasting]

Thank you!

[@assassinlexx1993]

I like your proud Australian maker's mark. Any black smith would be glad to show off your fine anvil.

[@AusMetalCasting]

Thanks mate!

[@joy6085]

I came here from watching the gentlest horse be re-hooved with a new shoe and found myself intrigued by the anvil. Wow! Top work!! 💯

[@innosyde7188]

what anvil? there is no anvil

[@stevechewning7741]

"Australian made is good" pride + skill + hard work.

[@baza1972]

Thumbs up for Australian Made!

[@paulkettle7690]

I want one ,love Aussie made

[@AusMetalCasting]

Email [e-mail] for order enquiries

[@jacobdegeling]

I didn't want this video to stop. Great work fellas.

[@johnblack6447]

Here i was about to sell my Peter Wright & buy one from that pommy in America (Alec Steele lol). Ill def be buying one of these 100% Please post up more vids of your casting & pattern/mould making,awesome stuff.

[@dragonwing4ever]

theres a few options for new anvils in aus , anyang does them so does bsl anvils both are extremely good options and reasonably priced too

[@FishyBoi1337]

Saw someone else mention the editing and I appreciate the honesty and acceptance of criticism, I hope whoever edits these the best of luck, as I know editing SUCKS. Looks like it's gonna be a gorgeous anvil though!

[@AusMetalCasting]

He mate, I'm actually the editor and have put so much hard work in to developing and learning this all quite quickly. The first video is the first video I ever made. I did all the planning, cameras, editing, youtube admin etc. By myself and it was so much work I wasn't prepared. The criticism hurt but I needed it and comments like this make it all worth it. I have learned so much and am excited to keep making videos. You made my day. Thank you

[@dakotareid1566]

@@AusMetalCasting get the app skill share there’s videography courses and video editing courses best of luck

[@Edward-xj4mp]

This is an excellent video, editing is fine. The content is superb!

[@TheAspiringLawgiver]

@@AusMetalCasting Coming from a former Combat Videographer in the United States Marine Corps, this was an informative and entertaining video to watch. Considering it's your first video, it's done damn well.

[@saidsahra15]

@@AusMetalCasting What do you mix with black sand to be that strong and hard?

[@douglasfathers4848]

I'm lost for words , How good is this watching you making anvils in Australia .

[@AusMetalCasting]

Wow, what a comment. We're speechless. Thanks for your support!

[@gabewhisen3446]

A tool that will last several lifetimes amazing

[@Mr_Bio_Hazard]

Didn't see any anvils being made.

[@dr.ibrahimhassan8501]

رووووووووعة لا حول و لا قوة إلا بالله و الله رائع اللهم صل و سلم على نبينا وحبيبنا وشفيعنا وقائدنا وقدوتنا محمد صلى الله عليه وسلم تسليما كثيرا وسبحان الله وبحمده سبحان الله العظيم.💘🍃💝🌾💚🌺❤🌻💙🏵💞🌱🧡🍀💓💐🌼🌷💙🌿💕

[@germancantu9847]

The anvil turned out really nice, great job.

[@innosyde7188]

there is no anvil

[@germancantu9847]

@@innosyde7188 yeah it was a sarcastic comment the video says "making a 100kg steel anvil" and after watching the entire video there was no anvil. I was anxiously waiting to see a molten steel pour but was only disappointed.

[@innosyde7188]

@@germancantu9847 I just found the other part(s) to the video. kzbin.info/www/bejne/jmqWn2OKaKqGhZo

[@ryanbarlet1265]

I mold aluminum casting it’s cool seeing other sand casting being done

[@joshschneider9766]

Sweet work. No bull.

[@AusMetalCasting]

No Bull ;)

[@brendanhayward1803]

australian made is good and there needs to be more of it

[@AusMetalCasting]

We agree! thank you

[@pby1000]

Agreed. This NWO crap has to end.

[@dale9896]

Great job well done!!!

[@AusMetalCasting]

Thank you for watching! Glad to hear you like it

[@jawdatfares2831]

Thanks again that was awesome to see keep up the good work we love you we love to see the final product part 2

[@justinthomas2458]

Very cool, thank you for sharing this process!

[@jamesburkhardt5143]

Love the videos...very satisfying for my creative side!

[@HAIDUCBLADES]

Great video. Subscribed. Please in the next video also film the heat treating part. I have never seen that anywhere and would very much like to. Thanks for the vid. Have a good day.

[@AusMetalCasting]

Heat treating was done as the metal cooled from the initial casting. It's not conventional but it works

[@beardyblacksmith7879]

Joey van der steg has a video where he heat treats an old anvil

[@lancemillward1912]

Looks bloody good to me

[@AusMetalCasting]

Thank you!

[@gabewhisen3446]

Amazing work men keep up the good work

[@tattoos1988]

Now this is what I like high quality hand made items you can see the pride and craftsmanship being used in each casting thanks for sharing I’m a new subscriber all the best

[@AusMetalCasting]

Cheers mate!

[@innosyde7188]

ur only getting a 'Cheers mate' because you subscribed

[@HariyadiAlemMusleh-fc4dj]

Saya suka melihat video pembuatan anvil..salam dari indonesia🇲🇨

[@stanleyjaxen5043]

Wow this is amazing

[@markward6076]

Wow !

[@jcgjcg3844]

He isn't lying Australian made is Good but American Made is The Best! 🇺🇸

[@scottpitner4298]

When he’s painting the inside I wanted to say “Don’t forget to get Down Under there”

[@liambain5070]

Haha Mike nolan the man himself love it

[@AusMetalCasting]

hahahahaa. Now you've said it I can't unsee it

[@andizell2255]

Thank you so much for this Video! You guys are rockstars!!!! I tried to find information about anvil casting and you are the first to post a proper video about it done by a real foundry🤩 love it, cant wait for the following videos

[@AusMetalCasting]

🥰🥰🥰 Thank you! Yeah I found lots of backyard melters but not many pros on here. We'll be making more than just anvils. Hope you enjoy it!

[@andizell2255]

@@AusMetalCasting I definitely will! Casting is a very interesting topic for me 😊

[@josephastier7421]

That mold looks like you made it out of concrete. Amazing work.

[@ledocteur7701]

it's resin sand, basically resin but in a powdery form whish is easier to work with, so yeah, it's essentially like concrete but that dries much quicker, is significantly more expensive and probably not quite as strong.

[@zaibmuda735]

Awesome Mr president...

[@HockeyVictory66]

Now I understand what sand casting, Honda used to make their motorcycle engines this way.

[@Tried_Original]

Great job

[@Sandwich4321]

Are you guys going to make another video with the pour and the final product?

[@AusMetalCasting]

We sure are! The next video is the cope, riser and closing the mould with the pour and machining / finished product after that. Stay tuned!

[@smoluk1]

Way to go!

[@marctrossbach6560]

Good stuff!! Makes me want to buy one

[@davidlenneberg4303]

Wow I didn’t know we made them in Australia any more.

[@MisterRorschach90]

You guys should make the worlds biggest anvil and take over the KZbin algorithm. I’m talking an anvil big enough for multiple people to stand on.

[@aldunlop4622]

“Dave, knock it off with the bloody angle grinder, I’m makin’ a bloody video!”

[@AusMetalCasting]

Hahahahahaha

[@rkgaustin9043]

Crikey!

[@NavySturmGewehr]

subbed. Excellent first video! Let's see more! Now I want one of your anvils but I imagine the shipping would be insane.

[@allnonsensewrenching]

Just found your channel and I'll admit, I'm hooked! Keep it up mate! --Watching from the United States of America.--

[@gavindooly2375]

I'm going to use the isomol paint trick for finer finishing out of the mould.

[@xanderalxandro6823]

My goodness, this is great video on so many levels. It highlights great craftsmanship, it is very educational and informative, and very entertaining too. I can't wait for Part 2. Off topic, I love studying, listening and comparing accents and I've noticed the Australian accent is very similar to that East Texas, especially the way some words are pronounced: People sounds like pay-ple Same sounds like sime Paint sounds like pint.

[@anamnesis972]

Hi ! What the sand's made of please ? Silicate sand + Water ? Or + Oil ? Thanks you very much~~

[@alteredchannel3549]

Trabalho bem feito!!!!!!

[@Ho1yhe11]

I am curious about how they melt the steel and how it does not remove most of the carbon

[@AusMetalCasting]

it does, we add more back in to allow for it

[@Ho1yhe11]

@@AusMetalCasting how do you add it back in, siliconcarbide powder?

[@AusMetalCasting]

@@Ho1yhe11 go and watch video 3 closely. It's in there

[@Ho1yhe11]

@@AusMetalCasting I watched the pour all it said was "adding carbon" and it was a black powder which could be siliconcarbide or coke dust or something else it was added before the metal was even melted which I would think would reduce its effectiveness Other things added were ferro manganese to add hardness was added when there were still some solid chunks of steel but a puddle of molten steel at bottom aluminum to help remove impurities added after everything was completely melted and a white powder which was unnamed to bunch the slag together I would assume this is limestone

[@FOOKYOUTUBENUMBERS]

Fooking great vid!!!! considering no anvil got made; to many beers rnd the barbie I suppose

[@rocifier]

This is awesome, can you freight these to New Zealand?

[@Jagdtyger2A]

I am curious as to how you can get a welded steel face on an anvil. My old Blacksmithing instructor said that the welded face anvils were the best

[@itsjusrex]

With cast iron there is a process in which you can pre-heat and then weld stringers of weld metal of your choice. Building up a layer. Then post heating as it cools Then surface the top and you’re done

[@hopebear06]

Subbed.

[@scottgage9541]

I would like to know how you recycle the sand from the mold.

[@maxbolshoynwykt]

Hello from Siberia! Can you please write what is your mold made of? I understand that it is some kind of sand with resin. We use mixture of sand and clay here when casting iron. We get iron from ore, reconstructing the methods of our ancestors.

[@hemidart7]

It's not called paint interviewer it's call wash and its made of zircon flower, the most heat resistant of the sand scale and very expensive so its cheaper to build the mold with silica sand. Some cases other sand is used in certain areas like Cera-bead, Chromite, Zircon all for different needs like chromite is used in areas that need a chill effect that is when you need to control the solidification in places you can't put an actual chill block (block of steel) zircon is used for areas where a lot of burn in happens and you need more protection anyway the wash is made out of zircon in most cases but there is other wash like when you do iron and manganese Steels and stainless is up in the 2700-2900 degrees pouring temps and need to be super heated sometimes up to 3000-3100 Ductile iron is much lower 2100-2400 so you don't need to worry so much about burn in the use of zircon not even fresh silica just recycled silica an its grey wash is all thats needed

[@user-nd3lx1zg9t]

Would have been nice if you had advised the this would be multiple parts.

[@rupert5390]

Geez really

[@bradmcconnochie3204]

Constructive criticism for next time, looking good so far!

[@ianbegg9851]

Awesome first video, very well done, they will only get better and quicker from here :-) I don't know why it took so long to find this channel :-) THANKS

[@scothubbard5323]

Was that burns on the guys arms that was applying the paint to the mold?

[@ronniebuchanan6575]

Blue Zircon mold wash. Greatest natural refractory ever. Tubelecane was the first foundryman he was a blacksmith that started molding shapes and casting not sure who the first guy to figure out there is metal in those rocks lets heat it up and melt it out. Boggles my mind on that one.

[@tehfuqizg0inon588]

Almost like something or someone helped tbe discovery process along

[@rickershomesteadahobbyfarm3291]

When did you make the anvil? I must have missed that part.

[@sudo_nym]

That’s basically the basics on basically casting a basic anvil.

[@kangmasdimpil2346]

Kesuen

[@hemidart7]

I worked in one of the best foundry's in the world making some VERY EXPENSIVE PARTS I wanna tell you something about the wash you are using we used to hand paint it on like you do in this video but the best way is to Flo coat if you don't know what that is its pouring on the wash and letting it flo off you want the wash to be a 65-70 buam'e this will give you a better cast surface with less porosity and burn

[@devemch7851]

Killer Video! What resins do you use in your sand? How fo you reclaim your sand?

[@shlomomenashe6324]

👍

[@ericritz932]

I love to have that

[@joshschneider9766]

wonder how much it would cost total to buy and ship one to the usa...

[@AusMetalCasting]

Send us an email so we can work out the shipping. [e-mail]

[@Kamikaziidare]

How do you ensure the face and base/feet are parallel, it doesn’t look like the machinists milled the base? Do you temper it back slightly? What average HRC is the face and horn? I’m in South Africa, was wondering what your price is?

[@Rich77UK]

Call me pathetic. But if i needed a 96Kg anvil I would absolutely want one with the Australian continent on its side. Looks Frickin awesome. ;) Rule Australia!

[@TheHeavensHell06]

Noice........

[@ramanand4221]

Did your machine shop make the top and the bottom square and parallel to each other? No website? How much does this cost! What are the two cylindrical nubs on each side?

[@seandepoppe6716]

And is there a part 2? Where we get to see the finished product?

[@tedykrisnapati2924]

it is difficult to cast iron in a melted state with a heavy load. because it will damage the mold.

[@babebful]

That was a great set of videos, quality product .about how many hours does it take to make one of those ?and what is the price?

[@b.h.customs2596]

What kind of pain do you use?? 💥💥Awesome Video 💥💥🤙🤙

[@sblack48]

Did he get some molten metal on his left forearm?

[@MichaelHarto]

Is this the guy bigstackd dump his scrap steel to?

[@wantafastz28]

Where does one in the US get that paint? What is it called exactly?

[@AusMetalCasting]

I'm not sure where you can get it in the US. We're setting up an online shop so you will be able to purchase from us

[@wantafastz28]

@@AusMetalCasting the closer side to Australia! Arizona is where I'm at, maybe u can do international orders!

[@AusMetalCasting]

That's the plan! We're working on the final anvil video and then that will be top the list

[@hardrivethrutown]

I'd recommend adding a (Part 1) to the title to avoid confusion Other than that, great video

[@amrohindi4551]

what type of steel you've used ?

[@_Jumbo_]

👍😊

[@everready19373]

What is that on his forearms, warts?

[@jamiesuvo7420]

If I wanted to buy one of these anvils where would I get it from please

[@rumbletumblestumble]

im a noob here but shouldn't you forge a anvil ?

[@matteyles7466]

Awesome stuff, do you do a swage block?

[@dbmail545]

Only in Oz do foundry workers wear shorts

[@AusMetalCasting]

Not when we're melting but the rest of the time it gets hot!

[@killjoy987987]

How long would it take to make one out of brass

[@hemidart7]

We tend to call those things filters but they're really not a FILTER! they will sit in the base of a pour cup called a Kalpur they regulate the flow of the metal

[@CottonTailJoe]

Where can one buy an Australian made anvil?

[@TohGahr]

Where to buy, and do you ship to the US?

[@mdimansantoso3976]

What kind of paint that used? it burned easily

[@jawdatfares2831]

I wont to have one of those anvils 100 kg haw to get one of them do sell them haw to contact with you sr

[@ppx4243]

Forgot the anvil bit

[@bearup1612]

So how much for an anvil. cannot find a website

[@draven3838]

How much for the anvil and how much to ship it to the USA

[@JLK89]

I'm curious about the environmental impact of the resin sand mould (microplastics?). You say the sand gets used twice, what happens to it then?