Metal Casting at Home Part 88 Audi Quattro MAF Pipe

I made 2 of these for a friend for a replica of the 1984 Sport Quattro. It gives the engine bay the correct look instead of a welded pipe or other strange looking solutions.. This pipe belongs to the road version of the Sport Quattro. You can see the part at the left side: here 12v.org/urs/SportQEngineBay1.jpg
The pure rally versions having a different intake system mostly build out of carbon or kevlar fibre.
The pipe is only 4mm thick and I was not sure i could cast a thin part like this but all came out well.
Creality 3D® Ender-3 Pro: bit.ly/2VXZMP6
Creality 3D® CR-10: bit.ly/2WGWlJI

[@wntu4]

So relaxing to watch this with NO MUSIC. Just natural sounds and the birds chirping.

[@eksine]

yeah he needs to do something about those damn birds

[@natepanek2330]

Ditto

[@niallsommerville9941]

And the Dyson.

[@phlodel]

@@niallsommerville9941 Yeah, that really sucks.

[@sammas7440]

Yes, it was nice to watch the video without all the loud over music and nonsensical over-talk. Good job!

[@counterfit79]

I imagine this guy watching early 2000’s DVD’s with the “you wouldn’t download a car” anti piracy ads and having a sensible chuckle.

[@onurmemis3618]

Highest quality castings on KZbin by far. Well done.

[@GypsyTinker2012]

This is a Master at work.

[@chrishayes5755]

No way I can reproduce those results. I'll have to wait for new laser sintering tech to become available lol.

[@occamsrazor1285]

Yeah, I thought the same thing. I've only seen casting being made

[@hamidhamid332]

educative.

[@borivojetravica569]

How about when you look in way how to do? Still no1?

[@ovalwingnut]

🔧🔩⚙⛏4 years have passed and I'm back for more of the same - it's that good ♥! You do realize when the "world goes to heck in a hand bag"... We are going to desperately need you. Thanks again! Cheers from So.CA.USA - 2nd House on the Right.

[@shadowdog500]

You can tell your knowledge and experience by how easy you make it look!

[@diecksl]

I saw this at least 50 times, but it still looks like magic to me when a finished part is extracted from the sand

[@davidtappe5337]

Lejf Diecks you should be making your own by now, video?

[@notyouraveragegoldenpotato]

Now THIS is the perfect union of my hobbies😂 old Audis and casting. I was JUST looking at a intake bi-pipe today thinking I could cast it and make my own RS4 bi pipe

[@ElliHoy]

thank you for not putting obnoxious music in your videos and leaving the relaxing bird noises in the background, 10/10 enjoyed with a cuppa tea

[@myfordboy]

I often have to turn the sound off when watching others. Why do they think their favorite head banging music suits the video?

[@stingy49]

I knew you were legit when I saw the raspberry pi box used as a paint stand!

[@dr.rumack7668]

Brilliant work of combining 3d printing, metal-casting and of course Audi quattro bits.

[@danielvandertorre7505]

nothing more satisfying than making your own parts a man with tools and the know how to use them is a real man anything else is just a imitation of a man .

[@hakanatalan8446]

Thank you, sir. I am a mechanical engineer with 20 years' experience and I watched your work with a lot of respect. It is great that you have combined the 3D printer technology to build the core and your model. This is great !!

[@kennedy67951]

Awesome. I've been watching you just about as long as you have been on KZbin. I've learned a lot over the years. Thank you for showing your skills to the world mate. IT IS VERY APPRECIATED.

[@Carswaps1]

I've got to be honest, the work that went into that,is just awe-inspiring! Incredible.

[@n03lr055]

That there is a craftsman, pure pleasure to watch and no BS commentary from a 15 minute fame seeker, thank you

[@johntenhave1]

Well, that was a tour de force! Standing ovation from the cheap seats in the Southern Hemisphere!

[@Aspins]

Brings back memories of watching my farther B Terry Aspin (Foundrywork for the Amateur ) casting on the backyard when I was a kid in the early 1950's.

[@myfordboy]

Nice to see you here. Your father's books are excellent and I taught myself the basics from this and his other book Foundry work for the ametuer. He was a great illustrator too.

[@Preso58]

Keith, I too have your dad's books. Such great resources for amateur foundrymen - and women.

[@tobhomott]

I wish I could find his books on Kindle!

[@Bobs1Models]

I too learnt from your dads books

[@Vinwelder]

Most unexpected person to see in the comments section on KZbin! Pretty awesome when ya get a comment from somebody like this 4 sure! Your dad was an awesome man Keith for sure! Pretty awesome to see ya following him too! Definitely following now sir! 👌👏👏👏

[@DudleyToolwright]

Those were absolutely the best quality castings I have seen on youtube. Fantastic job and your process was really easy to follow.

[@zoltanr15]

Quite an ancient art you do sir. Beatiful work, truly!

[@petergregory5286]

I would make a number of these because if Audi don’t stock these any more then there’s a niche to make a profit. Enough anyway to support your channel for a bit. Those castings really looked the business, congratulations. Regards.

[@MeltandCast]

They look awesome, your friends going to be very happy with those. Cheers 😃👍

[@Smallathe]

Fascinating work you do. I loved to see the integration of 3D printing with the metal foundry work. Brilliant.

[@justinturner4850]

I really enjoyed watching this handmade part for such an iconic car. So cool to see such craftsmanship.

[@vdubfrk]

Watching this video bring me a lot of memories back when i was in middle school and we used to do castings with silver, same procedure but with smaller parts! Great video!!! 👍

[@leop9021]

I first started watching your channel to see the "old way" of doing it. In this episode I see that the old way and the new way are the same way. The new way just substitutes a 3D printer for a wood working shop. Brilliant. Time to embrace the new way, old way, same way. Thank you for the insights.

[@fakiirification]

If the old timers had had CAD and 3d printing to make their casting models, you bet your ass they would have used it. The old way IS the new way, just with up to date tools and techniques.

[@leop9021]

@@fakiirification totaly agree.

[@genarorojas309]

A fine combination including precision, casting and knowledge sharing, I like it. Thanks for the lesson, Genaro (México) .

[@wesco123]

I have learned more in two hours worth of observing your great works than I have in decades of observations combined. Tipping my hat in admiration.

[@kevinmurrell9779]

Now this is the work of someone who has worked hard and mastered the techniques! Brilliant job!

[@StreuB1]

Top job. They came out perfect; as if they were fresh from the casting house in 1983!

[@michaelbutzen8122]

This is great work. This casting comes out perfect

[@deanbritton8441]

You are a very talented man ,watching you make these castings without a single word ..........Genius

[@BSMikkel]

Been watching your channel since cca 2012 Amazing work.

[@robertbeltowski2819]

Very impressive, great job. I do 3-D CAD printing and casting with my grand kids, I can appreciate all the work that you put into this. Thank you for showing us your skills.

[@steved8038]

Absolutely Brilliant just goes to show that with some study, and practice , professional results can be achieved by gifted amateurs your videos are both informative and inspiring thank you.

[@Machiflores]

I have just looked at it for a second time. Great vid. So clear and peaceful to watch.

[@mikemoise6539]

One of the most talented people on KZbin. Your videos are simple yet amazing.

[@IrishSkruffles]

I really like these videos where you recreate a part that's no longer being made, I still find it amusing that a 3D printer is so useful for foundrywork especially when some just classify them as useless toys!

[@fakiirification]

those who classify 3d printers as useless toys have no vision, and probably dont own a single hammer or screw driver. They are the type of people who call someone and shell out hundreds of dollars every time the least minor little thing breaks, instead of fixing it themselves. Those of us with vision and curiosity and the ability to turn a screw driver without anxiety attacks see 3d printers as literally the future.

[@FrankenShop]

That was really interesting, thank you for sharing it!

[@fokinlordsamaels]

in my opinion, the best backyard caster on KZbin. Thank you very much.

[@Dav5049915]

I've seen so many casting videos, this is the first one where the final product comes out perfect. Those parts look like they came off the factory floor. Impressive!

[@scottpeters1142]

And this is the first video I've seen. I love what you do. Always been curious of casting processes. I subscribed :)

[@nickzhang7862]

Thank you for posting this, I enjoyed it immensely. You made it look so easy! I see you also use Raspberry Pi. I don't think many have skills to use that and do metal casting. Keep going!

[@TheBussaca]

Best casting I've ever seen on youtube... fantastic work..

[@cyber4joy]

your video opened my eyes to how the core was done and what was done to place it right, thank you for sharing your expertise and experience

[@kirkc9643]

"...at home" by a master craftsman with years of experience by the looks. Nice work!

[@ME262B2]

I relayed the video saw you created a socket for the core plug to rest in. Didn’t see that upon first viewing. Thanks

[@Taz6688]

Every now and then myfordboy pops up in my browsing, I do when looking end up here for ages and am often ask "what are you watching" I cannot explain how watching someone perform magic and make something like this can be entertaining. As always its a pleasure to watch a "craftsman/engineer" do something like this, some people just dont get it, I do wonder how we would manage it left to todays children, some of whom dont know where food comes from, never put down their phones, and many dont like "hard work". Thanks for the high quality and informative video, top marks.

[@Made2hack]

Spot on with the core. The finish is absolutely brilliant!

[@mafosa8519]

Enjoyed every minute of this video. This is what makes KZbin great!! Larry

[@theonlybuzz1969]

I’m sure that the Audi owners will be really glad to have those, after all without industrious people like yourself they are up the creek without a paddle. Another great video for us to go over, can I ask a question about the core, you used tape to indicate the mould centre, when you had it in cad could you not put a locating pin that would correspond with the outer casting? Anyway still did a sterling job.👏

[@alextatkin1026]

OUTSTANDING. This was a pleasure to watch.

[@Clip7heApex]

Pure wonder across my face throughout. Amazing video and result.

[@darrylteichroeb9132]

You should seek out odd parts to cast for old cars. These will command a good price!

[@EddieOtool]

They do command a lot of work also at that point. 3D metal printing would be faster and about as expensive or less, although not as crafty for sure.

[@Lappmogel]

​@@EddieOtool Are 3D metal printing really on that level? I'm not saying it wouldn't work, i'm just thinking that casting it in one piece is a lot more solid then building it up layer by layer like those printers do.

[@EddieOtool]

@@Lappmogel I'm not up to date with current technology, for I am a bit removed from the field, but for aluminium parts (which is what he was casting I think), it should easily get resistance up to cast metal, because aluminium is easy to melt with a laser beam. I just found a machine who can do steel 3D prints up to 682 MPa (99000 psi) tensile strength, which is not bad at all. It actually compares to 4140 heat treated steel. So, no, I wouldn't be affraid of solidity. :)

[@Lappmogel]

@@EddieOtool I just looked it up (3d metal printing) pretty impressive. Obviously a part like this is going to be cheaper and better with regular old die casting since you can just reuse the same mold over and over again, but that's only if you mass produce one part. If you are into restoring old cars professionally and need to do one of a kind items all the time a 3d printer might pay for itself after awhile.

[@Waemdk]

​@@EddieOtool The thing is that collectors of rare and expensive cars don't care about the price and if its not possible to get the original part anymore they want one as close to the original as possible, so offen it will have to be cast. But i have no doubt that these parts can be metal 3d printed. Take a look at a company like desktop metal.

[@free_spirit1]

Today, on "knees of steel"

[@deankay4434]

+letsgetverydrunk Myfordboy has a link that explains he has pads sewn into the work pants. Another clever idea. Subscribe to his channel and you can read it Q&A page. Excellent execution of a process not many can master and has no reason to explain verbally his steps other than reading he comments to shop best practices in at home casting. With the price of propane in the states, I don't know if I could afford to create a foundry to melt my old casting parts into a new design engine brakes for external A/C, Alt and P/S pump for a fuel injected GM truck engine I am putting in my 1967 C10 pick up. $200 bought me a 65 C10 Apache a construction company had owned. The wood floor was soaked with diesel fuel, motor oil and waste oil for in field service of large machinery. I was 14 and took 3 years to save that money. Your license was for school or farm work. Maybe I will send my finished pattern and cast chunks and let him film that. Two thumbs up for talent. Retired because my doctor said I had enough, but still try.

[@eliduttman315]

@@deankay4434 Dean, several dual fuel foundry furnaces are shown here on KZbin. Propane gets things going and then a switch to waste oil is made. Waste oil includes stuff out of engine crankcases and fast food joint potato fryers.

[@deankay4434]

@@eliduttman315 That makes a lot of sense, but I missed it or was never shown. Perhaps I have not seen ones that talk or show that change over. I work in a two man shop in 1969, that I helped Carl build. He was a clever guy who quit a Chrysler dealer then 12 years in a speed shop. He balance rotating assemblies, install hard valve seats, porting, etc. In the states, the Arab oil embargo forced gas station to close, speed limits dropped from 75 to 55 MPH and "Odd-Even" gas days. If you license plate ended in an odd number, you could buy fuel on an odd calendar day. Thanks Jimmy Carter. Wore a sweeter, turned down the "WH" temp to 65 Degrees F and told us to drive less. That did not work on a farm. But, to heat his shop, Carl placed a 55 gallon drum outside and put a tubeless tire valve stem in the bung. We only air charged it to 20 PSI or so. The draft tube was 2" off the bottom and with a ball valve, length of gas pipe, it dripped onto a log inside his metal off the floor home-made fireplace. He took two heavy oil barrels with the 3 metal rings, off-set the flue transfer pipe to one end, then a length of normal fireplace flue, but welded a three-way pipe a couple of feet above it. We burn't waste motor oil and tranny fluid and placed a box fan behind it. I found out transmission fluid burns very hot and a good sized log or two would last the entire day. Melted the handle on a SnapOn pry bar sitting 3' away one day when it started dripping ATF. In that heater arrangement, I would expect the ATF to burn 3 times as hot as motor oil. Not only did we service them but rebuilt them as well. I was a seasoned 14 year old who started out 6 years earlier, hand sanding wood spokes on a Ford Model A for a farm realtor, also named Carl, who like old cars, when I was age 8. He had straight 8 gangster cars, Duesenberg & 5 others he had obtained when farmers where preparing to sell. He would but the farm & all, then sell when he was ready. I already had fixed two gas powered abandoned lawnmowers and a 90cc two-speed Step-thru Yamaha in a $20 basket, under my belt. Gas was 19.9 cents per gallon and jumped to 33 cents. People thought the world was going to end...then jumped to 60 cents. I bought a 65 C10 for $200 at 14 to mow yards in town and get around with a "School / Farm" permit. Just make sure you had a tank of propane & two bales of hay in the back, you where good to go. I would like to make a Foundry from 1/3 of a water heaters tank.

[@Larry1942Will]

@@deankay4434 I cast aluminum alloys firing on propane. My crucible will hold 16 lb. of aluminum and I can do 5 melts on one 20 lb. cylinder of propane which costs $18. So $3.60 / melt. I have a home made furnace which is probably not the most efficient. Plan is to build a bigger furnace with better insulation and fire on waste oil. These home made furnaces will also melt brass, copper & zinc. I like to use junk automotive casting, especially wheels. The results are easy to machine and very strong. I'm 77 years old and enjoy making things. I traded for an old Jet milling machine and bought a new Chinese lathe. Fun, challenging & once in awhile I make something useful.

[@deankay4434]

@@Larry1942Will I am with you Larry. Never too late to learn and discover new methods and ideas. Worn joints and too many lumbar fusions forced me into an early retirement, but still enjoy drawing an idea, using materials to make new stuff and fix broken things. Farm boy's and Tech's never throw anything away, so I will wear the "Hoarders" badge with honor. God bless you, Larry! Keep going... (Propane, same price in Omaha, NE.)

[@wino4340]

Beautiful, beautiful work ! Could watch you work all day

[@davidburke3802]

collision between old school and 3d printer... this is a real gem. thanks

[@davabran]

Thank you youtube algorithm.

[@joeh9399]

Our gracious overlord, master of all things.

[@argleplonidge5838]

Very interesting channel. Did you know that you can get reusable/releasable cable ties/zip ties. Also if you use paraffin or WD40 as a cutting lubricant while sawing, filling or machining aluminium alloys your cutting tools last a lot longer - also get a better finish.

[@GrayRaceCat]

@Argle Plonidge In my salad days making aluminum router templates for PC Boards I remember using a wax stick in a cardboard tube as lube for aluminum cutting, never knew it was paraffin, Thanks!

[@soulkeephl]

This is far and away the coolest thing I've seen on youtube in quite some time.

[@jessejohnson159]

One of the best casting videos on You Tube for the process you used! As good as it gets AND two great finished products. Thanks! Now to get my small home foundry set up to duplicate products like your's.

[@DoubleD132]

did you have an original part scanned or just develop the part in cad for the model to print? Awesome work anyways ^_^

[@greasysteve5671]

I'm sure with enough time on Google you could find blueprints

[@AlanCheek]

Nice! I went back a couple of times, but I couldn't see: what holds the core centered in the casting? I know it can't just lay on the bottom... Thanks!

[@myfordboy]

Please look here for a detailed description of how cores are located. myfordboy.blogspot.com/p/metal-casting-tips-and-faq.htm and this video kzbin.info/www/bejne/qXqlgoqeYpaYj80

[@DiscoFang]

The 2 ends lay on the casting greensand. The ends of the pattern halves were smaller diameter and those ends will not become part of the casting.

[@mute8s]

@@myfordboy Thank you very much. You need to edit your blogspot link to end with html and not htm otherwise you get a page not found and most people wouldn't think to try html when they ran into that error. Keep up the good work though.

[@kellerrobert80]

@@DiscoFang Thank you!

[@simonlewis1470]

Always a pleasure in watching you make something it's fascinating how you achieve the final result 👍🏻👍🏻👍🏻

[@andrewmichaud2395]

You're one clever fella, really enjoy all your videos. Thank you so much for taking the time to make them!

[@azyfloof]

Who else among us did indeed panic despite explicit instructions not to? xD

[@josephcperry]

By the way, did you scan the old manifold or measure and estimate?

[@princechannel2154]

I think scan

[@ldmoriarty]

I like the Mourning Doves cooing in the background. Thanks, Myford Boy. You make it look so easy.

[@Machiflores]

Wow excelent sample of worksmanship and knowledge. Thank you for posting this.

[@Saboteurbaron]

My question is: How could this made with just laing the core into the form? Is there a spacer inbetween?

[@myfordboy]

It's supported at the ends .Please look here for a detailed description of how cores are located. myfordboy.blogspot.com/p/metal-casting-tips-and-faq.htm and this video kzbin.info/www/bejne/qXqlgoqeYpaYj80

[@jh-wrkannon5592]

@@myfordboy Slight typo in your URL myfordboy.blogspot.com/p/metal-casting-tips-and-faq.html

[@chrislong6601]

Thank you for sharing this. I'm not a car enthusiast really, and my skill set is totally inappropriate to this kind of job, but watching you do this was amazing. Thank you for taking the time to make the video and for sharing it with us! It was really fascinating to watch!

[@ryandrew2588]

Likely Never going to do this in my life time but can't stop watching anyways...

[@howder1951]

Once again, you make it looks soooo easy! beautiful result. Well done!

[@zvonibab]

Now that is what I call complete professional, well done Sir

[@GaryLaaks1]

Well done. Looks real good. Somehow I can sit and watch this kind of work all day. Soothing to the soul somehow.

[@creamshop]

Soothing and relaxing to watch experienced Craftsmanship at work !

[@johntenhave1]

Stunningly good result. As hypnotic as ever.!

[@RosssRoyce]

Amazing craftsmanship! Thanks for video!

[@ykdickybill]

Well done mate. Absolutely brilliant. Bromsgrove green sand ! My family were all in manufacturing in Birmingham years ago. City of a thousand trades and Bromsgrove Green Sand !!

[@M3rVsT4H]

I do love a good casting video, and this tick's all the boxes.. Fantastic, thanks for sharing.

[@idontneednostinkingchannel6848]

Brilliant! Just stumbled onto this one and was instantly absorbed! Great video!

[@Panzax1]

Very impressed. Great craftsmanship.

[@powerpiep]

That is some major craftmanship right there! Great video of your work. Love it!

[@allthegearnoidea6752]

Very very impressed. You have amazing skill and far more patience than me. Regards Chris

[@spaken2768]

Watching this is almost therapeutic

[@adamanderson2178]

Excellent work. Well done . A joy to watch 👍

[@LastMinuteGarage]

Amazing job. You are definitely a craftsman.

[@garyhardman8369]

Excellent video, as always Sir.

[@uberDoward]

I love it - you're doing exactly what I'm hoping to get to: 3d printing the molds and cores needed to cast custom parts!

[@no23mk2]

Thank you. Your work is a joy to watch.

[@JulianMakes]

Super super job, I need to start priming and filling my patterns more, you’ve put mine to shame. Lovely finish.

[@libinzhang1204]

Have seen a lot of these casting videos streaming on youtube as a background diversion. Yours is the first one I've seen in a long time that actually employs hydrogen degassing, a drossing flux and thermocouple temp measurement, so much respect for that! Adding a bit of filtration in the gating system (fiberglass screen or ceramic foam filter) would also help keep that clean metal cleaner. For all those aspiring foundry folks looking to up their game I'd recommend the works of John Campbell and the American Foundry Society. I work in the aerospace industry in the aluminum casting supply chain.

[@themessenger5868]

Impressive ! The satisfaction must be tremendous. I wish I could do this...Thanks.

[@gregdimas3011]

Nice ring, and that sand is beautiful.

[@stevemcevoy5628]

Awesome 💯 job keeping the old cars going and not getting ripped of dealer prices and more satisfaction doing the job yourself . finished casting lovely.

[@argee55]

Excellent video. Love to watch your work.

[@thedude8046]

Wow I can see this isn't your first time casting, the part looks absolutely perfect well done!

[@Abrikosmanden]

That is some very impressive casting, right there!

[@davebrittain9216]

Hey Mister that is one heck of a nice casting!

[@scattkiwiman]

just discovered your channel, best tv ever :-) I had no clue how this was done. Wonderful !

[@garagemonkeysan]

Perfect every time! So cool watching this process. Thanks for sharing! Cheers! : )