My First Metal Casting - From a 3D Print!

Today's project is a big one...
There is a lot of learning, and a lot of work to get done, but by the end we'll finally finish the DIY 5C Drawtube!
• Make a Drawbar from DO...
We start off with sand casting the hand wheel using a pattern created in 3D CAD software, and then 3D printed.
We have a brief overview of the casting process, where we'll talk a little bit about the tools we use and how they're made, such as the homemade Kiln / Foundry.
Then, we'll cast the part using a petrobond mold, and Zamak alloy for the material. (ZA-12)
After that, it's off to the lathe for machining.
We'll do some general turning and facing operations as we begin to shape and cleanup the rough casting, before we move on to drilling and boring.
We'll bore to a close tolerance in preparation for the next step, which is to press fit the 5C draw tube into the hand wheel.
Once everything is assembled, it's back to the lathe for finish machining, where we will clean up all of the surfaces and bring them into concentricity with the draw tube OD, while also doing the final shaping and tuning the hand wheel for a nice comfortable fit in the hand.
I hope that you enjoy!
My Lathe: MSC / Prince 9517350 - 13x40 Manual Metal Lathe
My Mill: Bridgeport Series 1 J-head Variable Speed Milling Machine
Who am I?
I am Hersch!
I'm a hobby machinist, with a passion for old machine tools and manual machining.
My favorite place to be, aside from with my wife, is standing in front of the manual lathe.
I like to fix up and restore old machines, make my own tools, and I also take on small jobs fixing, or making parts, etc for others.
Why am I here?
I am here to share and learn.
Being self taught, much of my limited knowledge, has come from others sharing their experiences online, just as I am doing now.
This channel is my way of giving back a bit of that which I have gained from others, while at the same time hopefully being able to learn even more by putting my work in front of far more knowledgable and experienced machinists.
Music and Sound Effects courtesy of: www.epidemicsound.com

[@danmooney7192]

Thank you for that song at the beginning of the video. That has been my favorite Gospel song since the first time I heard it in 1968.

[@hersch_tool]

And thank You very much for watching! :)

[@johanneslaxell6641]

👍🏼👍🏼! My own guidelines: - If possible I like to heat/cool instead of pressing as it reduces stress. - The smaller mass of spinning parts the less vibration. - Admire people who put this much time and effort into making both functional AND beautiful pieces. The "beautiful" never happend for me, it allways stops with "function"...

[@hersch_tool]

Yeah I haven't actually tried the method of "heat fitting"??? parts together yet, but I'll have to try that on my next project with tight fitting parts like this. And thank you very much btw, I don't know that I'd say it's "beautiful" lol, but I do very much appreciate the comment. And for that matter, doesn't function have its own beauty? Don't sell yourself short, if you making stuff that works and is useful then you doing it right! And thank you very much for watching!

[@foogee9971]

Thank you for showing your work...as always, we enjoy watching your work in progress and your explanations. 👍 Great Job!

[@hersch_tool]

Thank you so much as always! I hope that your doing well!

[@emanggitulah4319]

Very nice video. Found it very helpful how you explained building your forge. I think you need an extra hole a riser that will help to get rid of bubbles and some of the the slack... Love to see more

[@hersch_tool]

Thank you very much! Yeah I think that would have helped, and someone mentioned adding tiny little air holes into the mold as well to help the air escape, which I think might help to prevent the mold breaking as well. LOTS to learn and keep practicing, so we'll definitely be doing more with the kiln in the future! Thanks again!

[@milanmarkovic522]

Nicely done 👍🏻 and I do enjoy the longer videos

[@hersch_tool]

Thank you! And thanks for the feedback. I wasn't sure how folks would like the 30 minute vid so I'm glad to hear it!

[@devmeistersuperprecision4155]

You did pretty good for your first try out. I will caution you about zinc. Zinc fumes can lead to foundary man disease. It is very painful and unpleasant. If you get it, best cure is several glasses of cold milk! The collapse in the bottom along with the tears has to do with shrinkage. The tears are called hot tears. You need to “feed” the cooling casting with extra metal. This is done with a riser. A volume of metal that freezes last. As the casting cools, it draws metal from the riser. Quick explanation for a comment.

[@hersch_tool]

Thanks very much. Definitely still have a lot to learn. I am doing some research on hot tears and how to make a proper riser, thanks for the info. Hopefully will have a new casting project sometime soon, definitely want to give it another shot. And thanks, you can't see it in the vid but I was wearing a respirator while I did the pouring, but I'll be sure to look out for fumes and will keep the milk tip filed away for emergency use only lol. Thanks again!

[@joell439]

That really came out phenomenal. Thanks for the whole story of what it took to get here. 👍👍😎👍👍

[@hersch_tool]

Thank you so much! And you're very welcome, it was quite the adventure... 😂 I hope to try some more casting soon! And as always, thank YOU for watching!

[@scottpageusmc]

I was born and adopted in 1977. In 2015 I took a DNA test and connected with my biological mother and father. I'll spare the details, because they aren't important for what I was wanting to say. Except for the fact that I'm musically inclined because of them. I've always loved the song you choose for the opening, Bridge Over Troubled Water. In fact, I have a deep voice, and have sang mostly Johnny Cash and Elvis songs. I was born the day after Elvis died, August 15, 1977, so that's a bit special for me. Anyway, I was called "Little Johnny Cash" in Louisiana and Derby, England (long story) decades ago, so I sing. Bridge Over Troubled Water is the only song I can't sing without shedding a tear. I damn near can't sing it all the way through in public. I grew up listening to it, because my parents were Simon & Garfunkel Dana fans. What's really funny is that my Dad looks just like Simon on the cover of his "Still Crazy After All These Years" cassette. Mustache, hat, and all! I still give my old man a hard time about it today! Anyway, again, thanks for the great memories and awesome video!

[@hersch_tool]

Thanks so much! And thanks for sharing a bit about yourself. My dad is a musician, I've been watching him play my entire life so music has always been a big part of my life. My cousin and I actually recorded an album once haha, but that's another story from another life... Side note, my b day is Jan 8, same as the King 😉

[@scottpageusmc]

@@hersch_tool ha, that's so awesome! Hey, I just wanted to thank you for doing what you are. Your work is worth watching and so cool! Oh man, you share his birthday! Unfortunately, I share his death day. No matter, we're brothers!!!

[@hersch_tool]

@@scottpageusmc Brothers in the King! And thanks for that, seriously it means a lot. There is a lot of work that goes into these vids, on top of my full time job. But comments like yours make it all worth while. So thank you :)

[@billjohnson5793]

Well done…thank you

[@hersch_tool]

Thanks very much! And thank you for watching! :)

[@perseverance_1]

that is very interesting. You are very talented. thank you

[@hersch_tool]

Thank you so much! That's very kind. And thank thank you for watching!

[@rescobar8572]

Keep up the great work! 👍🏻

[@hersch_tool]

Thank you!

[@ferrywobma1836]

What I'm missing in this video is applying the final product? Because the tube was cut too short, I was curious how the handwheel would ultimately fit on the drawbar. Furthermore, very clear explanation. Greetings from the Netherlands.

[@hersch_tool]

I just changed the way that I connected the handwheel to the tube. Originally, I was planning on pressing the tube through the entire handwheel so that it would be flush with the back of the handwheel. Instead, I bored the handwheel through to the ID of the tube, and then bored a 3/4" section to a press fit on the OD. This made up the difference that I needed from cutting the tube too short. Thanks very much, and thank you for watching!

[@edsmachine93]

Nice work. Very nice project. I think that the casting came out nice for your first time.👍 Have a great day.

[@hersch_tool]

Thanks very much. It was a lot of fun. I definitely learned a lot and think the next one will go even better. Looking forward to trying some different materials as well. Have a great day!

[@robertfontaine3650]

That zamec casts and machines very nicely.

[@hersch_tool]

Yeah, I think it makes a good material for general applications that don't have to be super tough or wear resistant. And it flows almost like water so should be great for highly detailed patterns. I'd like to try some more projects with it in the future.

[@robertfontaine3650]

@@hersch_tool I've watched the cast iron videos and it takes a more commitment to casting. The higher heat means a lot more safety and the cost goes up. Zamec is a pretty easy entry.

[@hersch_tool]

@@robertfontaine3650 yep, I recommend it. Though I would like to try iron in the future.

[@kep-kraftindustries3759]

Great job on the casting and final piece! I have always been interested in casting but never took the plunge into trying it.

[@hersch_tool]

Thanks very much! I definitely still have a lot to learn. But I learned a lot from this first attempt, and plan to do more in the future so hopefully they'll get better and better. :) And you should give it a shot! It's a lot of fun, and it's very rewarding. Thanks again, and thank you for watching!

[@pikeyMcBarkin]

Really enjoyed this video.

[@hersch_tool]

Thank You very much!

[@mateobarbis3628]

Awesome!!

[@hersch_tool]

Thank You!

[@robertskelton2576]

How about some info on that tool holder. Never saw anything like it. Zamac just think of Atlas & Craftsman lathes.

[@hersch_tool]

Which tool holder do you mean? And yep, a lot of parts on the atlas/crafstman lathes were made of zamac. It's pretty decent material for hobby shop use. Very easy to work with, and gives an acceptable result. And if something ever wears or breaks, just melt it back down and remake it! 😂

[@VanoverMachineAndRepair]

What camera are you using. Is it an iPhone. The footage looks really clear. Thanks nice work.

[@VanoverMachineAndRepair]

I am really digging those boring bar shots whatever lense you are using has a small minimum focusing distance.

[@VanoverMachineAndRepair]

I am really impressed. I am learning from you. Great job really, awesome shots!

[@hersch_tool]

Thank you so much! And yep I'm just using my phone 😂 ironically enough I do have a nice camera that someone gave me to use for the channel but it's so difficult to use that I prefer the phone because it's simple, small and easy to deal with.

[@jameshicks6753]

First time around on a casting.😅 Well remember no guts, no glory. Casting never look good coming out of the sand. Other then the lack of trust to try and clean up the back side, it was a outstanding accomplishment Push your self a litter bearded next time 😮

[@hersch_tool]

Thanks very much. I'm looking forward to doing some more casting in the future.

[@ellieprice363]

Good job. A big hunk of aluminum would have been easier to machine but not nearly as interesting as casting.

[@hersch_tool]

Thank you very much. And yeah definitely would have been easier. But I wanted to push myself and do something fun and interesting, as sort of a little thanks for all of the support that I've gotten on the channel. Thanks for watching!

[@camillosteuss]

Hah, the moment i saw those silvery ingots, i knew its was zamac... Been watching too much Pauls Garage lately i guess... Tho, that nonsense notwithstanding, i would consider adding a thrust bearing between the spindle and the handle... Zamac will wear down against the steel spindle for one, and even if you are able to ignore that fact, the quality of the clamping action will still suffer from soft metal to hard metal friction... Even if you cast it in steel like an anvil, i would still recommend the thrust bearing, as it will significantly increase the clamping on the collet, while at the same time significantly reducing the hand torque required by the handle to do the job... All the best! Also, bruh, whatchutalkin`bout? Too long? Im considering dropping a few hour long videos... Hell, im getting to the point where i need a better pc to merely handle the raw video data for editing without crashing... You make enjoyable videos, if people are in a hurry, they can skip and pick out what they want to see... For the rest of us who have longer attention span than a chicken and actually watch stuff like this for either inspiration or as a background while machining or doing something else - 3 hours is not too long... I sometimes watch 2 or 3 of Stefans shop talks in a row when i am drafting some design or just contemplating some projects...

[@hersch_tool]

Haha thank you! Glad to get good feedback about the video length. I enjoy longer vids as well, will keep that in mind in the future. And there is a thrust bearing. That's why the "adapter" piece is there. I have a video on when I originally made it if you're curious. It's called " "semi universal" adapter for a 5c collet Drawtube" cheers!

[@camillosteuss]

@@hersch_tool I think i have seen all of your videos by now... Not sure... Have had quite some mad shit happening lately... I think i cracked a bone in my arm... A piece of my custom hoist blew... Well, the custom part is okay, its the damned store bought winch that exploded a bolt into my lower wrist... I know the feeling of broken bones... This is the same thing, just not as bad, and obviously not a break... Between that and all the work in the meantime, my memory kinda has to be defragmented for the lack of a better word... Last few weeks are just a haze of work, smoking and sleeping like 4 hours a day most of the days... So i dont really recall if i saw the original video... I think i have... But anyway, glad that its been done... A good tactical move, also well implemented, i tried to inspect the frame of that adapter, but could not really say if there is a thrust bearing or is it just a decorative groove... Nice work at any rate and you are most welcome on the feedback... All the best and kindest regards!

[@hersch_tool]

@@camillosteuss Yikes... Be CAREFUL man. These machines are heavy, dangerous, and will not hesitate to remove pieces of you if you're not careful. I know that you know that, but sometimes it's good to be reminded. I know that sometimes when i start getting to "comfortable" it's easy to start pushing limits or taking unnecessary risks. You still have videos to publish so you're gonna need those hands lol

[@camillosteuss]

@@hersch_tool Oh, i know, i took every single precaution, the machine stand was lifted with a pallet jack and so on, and the lathe bed was blocked up on slabs of wood to protect it from falling, i was on the side, fully out of the way of anything that could fall, but i didnt account for a piece of sheared off steel bolt coming at me... Hell, i was filming the whole thing, but the camera died half way through the 3 hours of work.. So its a shit job in every way other than the fact that the machine was completely uninjured and the damage to me is negligible... It hurts, but a crack heals fast enough and leaves no disability, so i wont bemoan it... I just didnt expect the certified winch to suffer a catastrophic failure of that sort at what i assume to be a load well within its rated range... Tho, on the plus side, it made me damn proud of my welds and fabrication... A video was recently released, i think its called complacency kills - the lathe, or something like that... Look it up... Its a bit gory, but i think its a good thing to at least hear while looking at something else, just to be potentially informed on some scenarios that can happen... And it will make sure that you never ever make a lathe spider with protruding bolts when set screws of all sizes exist... All the best and thanks for the kind words!

[@UrbanaWoodProject]

I got a bit uneasy when you first suggested that you shouldn't pack the casting sand down too much. I think a better cure is to invest more into mold release efforts. But I'm guessing you already concluded this after the mold didn't hold shape.

[@hersch_tool]

Yeah, I think the tighter you can pack it the better is a good general rule lol. There's a lot to learn with casting. A lot of "finesse" I guess, especially in the mold making. I want to try some more casting projects soon. Thanks very much for watching btw!

[@UrbanaWoodProject]

@@hersch_tool If you do another video involving casting, I would love to hear your thoughts on zamak and where you would and wouldn't use it. Actually, it would be great to have a general review of the types of metals that can be DIY cast and what their place might be in machining projects (and where to avoid them).

[@hersch_tool]

@@UrbanaWoodProject that's a great question. I'll make sure to include that sort of info in the next casting vid. Thanks! 👍

[@kurb0311]

What's that rotatable tool holder called?

[@hersch_tool]

It's an aloris integrated tool holder. BXA-20 I believe is the number. It came in the box of stuff with my tool holder when I bought it, but they have them on MSC. Just search for your size tool post, number 20, So Axa-20, or bxa-20, etc.

[@kurb0311]

@@hersch_tool found it. Thanks!

[@hersch_tool]

@@kurb0311 no probs!

[@jeremyhicks6889]

Neither half of the mold was packed hard enough. Your sand looked like petrobond. Petrobond should give a good surface finish if properly packed. The top of the torroidal portion looked OK, but the bottom and the neck show signs of air space in the sand.

[@hersch_tool]

Yeah I think you're right. I was initially having problems with the mold not releasing because I guess I was packing it "too" tight. Certainly much more to learn, I plan on trying more castings in the future, so hopefully I'll get there. Thanks for watching!

[@67cudaksa34]

i little suggestion. i would have frozen the draw tube and heated the casting. that would have made the press easier.

[@hersch_tool]

Thanks very much! Those are good ideas. I considered doing a shrink fit but in the end decided against it because I don't have the means to cool the part as much as would be ideal, and I was hesitant to put a torch to the zamak as it's melting temp is right around 800-1000F. The press fit did the job well though, and there "shouldn't" be a need for a grub screw, fingers crossed anyway... 🤣 But thanks for the good feedback and ideas!

[@zedostenso3069]

Check Machinist Handbook too see what the expansion rate is for aluminum and melting temp. Cheers

[@hersch_tool]

@@zedostenso3069 Thanks!

[@dave9766]

I think I'm the first commentor :)

[@hersch_tool]

I think you're correct! I don't want to pick favorites or anything, but... haha 🤣😂 Thanks for watching!

[@Telephonebill51]

So, what's a draw tube already?

[@hersch_tool]

@@Telephonebill51 It's used to draw a collet tight into the spindle of the lathe. I could maybe do a short explaining it better if you'd be interested.

[@justaguy4788]

Stolen TOT format. nope

[@baddonkey6876]

Stop with the hand thing, it's annoying as hell, love the machining though, keep it up just stop the hand thing please

[@aguycalledlucas]

Unbelievable that you feel comfortable making comments like this. It’s rude as F and more importantly I know you wouldn’t do it to his face so please be a little more polite.

[@liamkelly8684]

The hands ur not tot