Metal Casting at Home Part 40 Aermotor Engine Block

[@pheenix42]

After the holidays here, I'm going to get a small furnace together. I remember a vocational class in high school where we did aluminium castings and I never forgot the enjoyment I got out of the process!

[@mcgrorymachined7596]

I love your videos because while explaining everything in great detail is good, sometimes is nice to just sit back and what the handy work happen!! thank you for another great video, just subbed etc!

[@dawesy041972]

another excellent video. would love to see a series of videos covering the machining and construction of this engine. keep up the good work, always a pleasure to watch.

[@kiplindsay1250]

These videos are wonderful therapy. An education while relaxing

[@muskokamike127]

That's the most complicated pattern/mold I've seen yet...good on ya!! Did you make them on a CNC router or do them by hand? After watching your videos you can see why when you buy something cast (in plastic or metal) that sometimes the halves aren't aligned perfectly.....you do an amazing job of getting your halves to line up exactly..... I make wooden toys/models and often there are parts that just won't look right out of wood.....you've inspired me to take up casting to make parts like: engine blocks, carbs, radiators, rear view mirrors, wheels.....and all the undercarriage mechanical bits.... I also build wooden boats and your methods are perfect for casting small cleats, lights, window frames, and other fittings.... I can't thank you enough!!!

[@myfordboy]

michael C No CNC just woodworking tools. Patterns are mainly MDF. If you make model boats you should have no trouble making patterns for your projects.

[@muskokamike127]

myfordboy and I have a cnc! haha....You're a great fabricator if you made that engine pattern by hand...that's truly amazing.... One thing about a CNC it can take care of the tedium of making things like the cooling fins, etc. then take over with hand tools. That's what I use it for. I'm just gathering my materials to make my small first time forge. Funny thing is? I live in a small town and plan on using a 5 gallon steel bucket but am having a dickens of a time finding one up here lol...I thought for sure I could get one at a local garage for hydraulic oil, or ?? but they're all plastic now....I might have to order a new one...(gasp)

[@myfordboy]

michael C When i built my 2 furnaces i could not find a suitable metal container so used sheet steel for the outer casing. kzbin.info/www/bejne/qJfJYWmdf8eGoqs and kzbin.info/www/bejne/qoWzlayYqbRgl5I There are some details of the furnaces here myfordboy.blogspot.co.uk/p/development-and-construction-of-my-oil.html and myfordboy.blogspot.co.uk/p/myfordboys-furnace.html

[@muskokamike127]

myfordboy yeah, I don't have access to a slip roller or sheet metal on the cheap. Otherwise I would do that.... I don't want to spend a lot of $$ at first. I've got access to quite a lot of aluminum spray cans, soda cans, and aluminum scrap and before I get too far into this, I just want to get my feet wet. Funny, I did find one...guy says "oh yeah, I have one..you can have it" only problem was: it was full of hardened adhesive lol....it'd take me a month of sundays just to get it out hahaha I tell you how bad it is getting materials up here (mid Ontario Canada/Muskoka): I can't even locate mahogany to use in my boats and other small projects! I have to either pay $40.00 (20 quid) shipping for $10 worth of wood, or drive 4 hrs.....

[@creast56]

Another great video. Last time I contacted, you were on 2D CAD. I see you are on 3D now :-). Great work, I always admire your skill.

[@termlimit]

Been watching you since before this video came out. I am always blown away by your videos. I finally purchased a Devil Forge and have begun my casting adventure. May I ask how you create such detailed wooden patterns? That I find an art in and of itself. Thank you and all the best in 2023.

[@myfordboy]

I have some videos on wooden pattern making here is one, there are others if you look through the video list.kzbin.info/www/bejne/Y6S0dH1sp9toatU

[@termlimit]

@@myfordboy brilliant thank you!

[@alphapoppio]

Absolutely amazing, and yes, I would be interested in both the plans and some more detailed videos on the build. Great work!

[@Bobcat1963]

Job well done again myford, you always do a successfully job on your sand casting. Glad you had a new video up.

[@MrGoosePit]

Amazing video as always. A true work of art. Greetings from suburban Chicago (not far from mrpete)! -Kevin

[@vasilispapameris5105]

Mr Pete talks too much

[@suabroboro]

I think the cement will set only when it is mixed with water but if we mix only the powder with clay it should work and also it's not so explosive that it will burn because you can see examples around you like suppose if you try to burn it ,it will not be burned easily .Also there will be an advantage if we add normal sand to the cement and do the test because it's nearly impossible to burn the sand.So I think we can use it for moulding.

[@andrewbishop7066]

Very impresive thanks for taking the time to make your videos Andrew

[@paulduffey7975]

Exceptional casting work and beautiful engine. Thank you.

[@chunninjitsu5265]

Virei fã de vocês. Gravei cada vídeo. É uma verdadeira, estupenda e maravilhosa aula sobre fundição e suas técnicas. Muito obrigado por ter compartilhado essa maravilhosa arte.Estudo MECATRÔNICA e essa área faz parte. Que Deus ilumine e proteja vocês. (bem que poderiam de vez em quanto mostra este Sr. que é um fera nessa arte. O mundo precisa conhece-lo).

[@SALTYCOMBATDIVER-ExInstructor]

Always a pure joy to see your castings! Thank you!

[@joshdrexler8773]

Wow! Very complex casting for a home "amateur." Hats off to you, sir. What did you do for a cylinder sleeve, and how did you fabricate & machine the crankshaft?

[@myfordboy]

Crankshaft was silver soldered fabrication. Silver steel rod and steel webs fitted at an angle and filed to shape.

[@myfordboy]

Cylinder has a cast iron liner.

[@brownkayola1964]

Wonderful video, educative. How do you ensure that there's even filling of the cavity(s) by the molten metal. Do you ever work with multi-cavity moulds in sand casting?

[@myfordboy]

When the metal come up the riser you know that the mould is full. Yes sometimes i do several smaller castings in one mould.

[@rchopp]

Nicely done, all your videos are top shelf. Really enjoyed watching the engine run.

[@RoboCNCnl]

Great project as always... What is the purpose of the diagonal piece in the pattern box? I see those a lot, are these just to make the space smaller?

[@myfordboy]

It's just to save sand.

[@av8ordavvee]

Beautiful! Does 8 cycle not mean "hit&miss"?

[@myfordboy]

It's 8 cyle AND hit and miss. The timing only allow the engine to fire every 8 stroke instead of the usual 4. So it goes intake, compression. ignition, exhaust,exhaust,exhaust,exhaust exhaust. On top of that there is a govenor which cuts in when the engine reaches the required speed so the the engine does not fire that often.

[@jimholesaw6597]

I love the smell of a fresh cast

[@TheYumChannel]

Wait what happened to the core you put in there before pouring in the aluminum? I’m not sure I saw it after you let it cool? And how did you remove it since you cannot separate the two sides?

[@myfordboy]

The core was dug out with some stiff wire.

[@TheYumChannel]

@@myfordboy aaaah that makes sense. I'm very new to this and I'm really curious how it all works. Thanks!

[@hayati4522]

Teşekkürler! Paylaşımlarınızın her biri mücevher değerinde.

[@suabroboro]

It's really a nice video.But can you please tell me will there be any problem if we mix cement with clay and use instead of greensand?

[@myfordboy]

I have not heard of that material used as a mould. If the cemet sets you would not be able to remove the casting and cement carries the risk of explosion.

[@KamWhite]

Is this aermotor something that is used in a windmill or what is the purpose of the aermotor? Did you use aluminum or some other metal?

[@myfordboy]

Yes it's aluminium. I have a detailed description of the engine and it's use here myfordboy.blogspot.co.uk/p/aerm.html

[@9sec93lx]

I'm always amazed at the skill level you exhibit in all your videos. Are there any books out there that would be good to read/study to learn your craft? Books on pattern making, sand casting or machining that you recommend?

[@myfordboy]

I have some casting books recommended in the FAQ page at myfordboy.blogspot.com These are the ones I read to teach myself.

[@paladin0654]

Talented guy, nice work.

[@cringegallery3468]

absolutely fascinating. I'm working on a project, and casting like this could be indispensable to making it. question, how well does this method of casting hold up for extremely fine, or really small applications?

[@myfordboy]

The finish is dependent on the fineness of the sand. The castings have a "cast" finish which suits the models i make. A better finish can be made using Petrobond sand. I would say not really suitable for very small parts.

[@koepketube]

Have you considered a 3d printer for the mold since you've already got it made up in the ol' computer?

[@myfordboy]

3D printing would be the modern approach but I like using the traditional skills.

[@65BAJA]

Are you going to do a complete series on the building of this motor?

[@myfordboy]

I have already made this engine and don't plan on building another but I may show a few machining operations on some parts.

[@funkyole1125]

very well done. will you be offering these castings as a kit like the stove fan?

[@myfordboy]

If there is enough interest, yes castings and plans will be available. I have more details here myfordboy.blogspot.co.uk/p/aerm.html Judging by the interest so far it looks like it will be possible.

[@americhal]

Muy bueno sólo tengo una pregunta para usted. ¿La tierra para los moldes como se prepara? Gracias

[@myfordboy]

The patterns are made from wood like the one in this video Metal Casting at Home Part 15. Pattern making, start to finish.

[@hoangha9942]

what is the thinnest object could be made by green sand casting?

[@myfordboy]

It depends how large the item is. If it is large the metal will cool before iti able to fill the mould. I can do a 6" disc about 3/16 thick OK.

[@MrLukealbanese]

Superb work as always!! What CAD package do you use? Is How difficult is it to learn?

[@Mentorcase]

Great video, very inspirational. On the cylinder is it going to have a lining installed?

[@myfordboy]

The engine has a cast iron cylinder liner.

[@louisdale7115]

Thanks for your videos always very good,a nice job Louis

[@bensthingsthoughts]

I'm just wondering, did you made any videos about recycling dry red sand ?

[@myfordboy]

I have this one kzbin.info/www/bejne/eam4lGxog5V4bLs

[@king9096]

how many loss al scrap weight from forging? how to reduce aluminium loss caused by aluminium oxide.. sorry for my bad english

[@myfordboy]

Hope this answers. Any dross, paint and impurities is scrapped off the top of the melt.

[@king9096]

@@myfordboy ok thanks

[@vivalesvegas]

I'm slightly confused as to why it's an 8 cycle. Is it to keep the engine speed down?

[@myfordboy]

It's fuel economy, an early eco engine? The flywheel keeps the engine running smoothly and only an occasional firing stoke was necessary. The fuel tank is small, the engine could be started and left to run until the fuel ran out by which time it would have pumped enough water to fill a storage tank.

[@markfryer9880]

Myfordboy, in this video in the background when you are in your workshop there appears to be a model traction engine sitting on your workbench. I am sure that many of your viewers would love to see it in action sometime soon. Is that at all possible?

[@myfordboy]

Mark Fryer It's a Fowler ploughing engine. Not complete yet, I'll show it some day.

[@BrutusJones]

What software are you showing in the video? Thanks for a reply.

[@myfordboy]

This is ViaCad

[@BrutusJones]

@@myfordboy Thanks, it looks good.

[@nickyrc3505]

A wonderful video.. It's really helpful, pls make a video on making a worm Gear.. Thanks

[@myfordboy]

Worm gear video kzbin.info/www/bejne/Y6bQlISqp9NkebM

[@ThingsHybrid]

is it possible to make a jet engine from foundry and forging from scratch at home and make it work?

[@myfordboy]

Quite possible. Search for gas turbine builders association.

[@superiormusic]

Your work is always a pleasure to watch :)

[@blackcat9147]

Really interesting!

[@camlowe4392]

hi I would be interested in castings and plans for this engine. a friend has a real one and I love his engine. are you planning on doing a pump for it as well?

[@myfordboy]

I may well do the pump. I'll put some more details about the castings on my site myfordboy.blogspot.com later today.

[@myfordboy]

Thank you for your interest. I have now added the information on my web page: myfordboy.blogspot.com

[@hoppercar]

What is the point of having that angle brace in the flask ???

[@myfordboy]

Less sand is needed. I only had a small amount.

[@CarterCreekFarm]

Great work! You make it look simple. How many hours did the pattern take to make? Was It made on CNC? Thanks for the Video.

[@myfordboy]

The pattern was made in the traditional way with hand and power tools, no CNC. I did not record the hours, it was built up over a period of time, the odd hour here and there whilst the glue dried.

[@CarterCreekFarm]

I thought you would build it up the old fashioned way. From start to finish you are a talented person. Thanks

[@paulmcguire3789]

very good video, I have like every one of your videos that I have seen

[@MrRocket721]

Nice work !! Love your projects !!!

[@fsecofficial]

What happens to the sand and sodium silicate?

[@myfordboy]

Broken out.

[@vforvendetta4538]

is it running on compressed air gas or liquid fuel

[@myfordboy]

+colin chapman Butane gas

[@vforvendetta4538]

+myfordboy thanks and very cool engine

[@tzkelley]

Great video! Did you happen to film the making of the pattern?

[@myfordboy]

No, I made the pattern about 7 years ago.

[@adirondackcarfoundry368]

I wish you did castings on commission.

[@changsifon]

My first subscribtion after 2 years ;)

[@RoboTekno]

Wow, just amazing. I hope one day I'll know how to do half the stuff you show on this channel. Well done :-) Do you have any videos planned to show the machining of the raw casting in this video?

[@myfordboy]

I have already made this engine and don't plan on building another but I may show a few machining operations on some parts.

[@OstazFarid]

nice work...how much that engine which you make??

[@myfordboy]

+OstazFarid Do you mean how much do I want for it? It's not for sale. I have castings and plans if you would like to build one.

[@OstazFarid]

myfordboy thanks for replay.

[@Friedrich-Wilhelm-1980]

a hit and miss from scratch? you sir are a good man for keeping a craft alive i would to try this i love casting but i sadly don't have my own foundry

[@MilanDupal]

Great machinist performance!

[@mauriciolima1088]

So beautiful thank you!!

[@robertofreware1]

Parabéns amigo adoro os seus vídeos, um abraço aqui do Brasil.

[@nongdrenkhombameitei8500]

how did you make the wooden model from the CAD model

[@myfordboy]

I Just used standard woodworking skills. I have a video showing the build of my steam engine pattern which is similar.kzbin.info/www/bejne/emK5mKmMmNR-erM

[@imdowncow011]

How do you make the wooden patterns

[@myfordboy]

I have some videos that show this. Metal Casting at Home Part 35 Pattern Making Start to Finish Metal Casting at Home Part 22 Flywheel Pattern Making & Casting. Metal Casting at Home Part 15. Pattern making, start to finish.

[@alaricy]

Have you 3d printer for patterns?

[@myfordboy]

No, I have woodworking tools.

[@FredMiller]

Gorgeous! I would be very interested in details about castings if you offer them.

[@myfordboy]

I'll put some more details about the castings on my site myfordboy.blogspot.com later today.

[@zedjo02]

Nice, very nice, thanks for your videos explaining all.

[@donaldasayers]

I have never known why it is called greensand when it's red? Always puzzled me.

[@myfordboy]

Green sand is not green in color, but "green" in the sense that it is used in a wet state (akin to green wood).

[@Firefly_serenity]

Its called green sand because its wet, the same idea applies to green (wet) wood. I've seen green sand of all sorts of colors depending on the actual sand composition.

[@av8ordavvee]

What CAD system are you using?

[@myfordboy]

ViaCad

[@elysegriffin3465]

+myfordboy

[@davidabbott6640]

myfordboy ViaCad

[@daviddonoho]

Super cool!

[@tareklakehal7713]

مشكورين

[@brozems7081]

that wooden pattern how did you make that

[@myfordboy]

I have some videos on pattern making kzbin.info/www/bejne/emK5mKmMmNR-erM kzbin.info/www/bejne/rYLZg2ObfMaXpqM kzbin.info/www/bejne/Y6S0dH1sp9toatU kzbin.info/www/bejne/iWfNdoarrdyUn80

[@brozems7081]

myfordboy what? you made the engine in that way thats amzing thank you so much

[@LarryMMackey]

Great video keep them coming!

[@samermarija489]

How you made corebox?

[@myfordboy]

This core is made in 4 parts glued together with core glue. Box is wood for the body and plastic tubes used for the round parts.

[@samermarija489]

Nice. I work in this industry (making models and coreboxes) and your videos are very interesting

[@limpdickit]

cool...beautiful work .....

[@cameronnulton739]

How do you make the cores?

[@myfordboy]

+Cameron Nulton This video shows how the cores are made kzbin.info/www/bejne/Z3nYqXeMpd6Sn7c

[@titoalvesfeitosa]

Man i would like só much só much for you haver take ir off all My queations about how this is Madeira thanks só much 😭

[@blazin20s]

excellent work

[@hollowpoints9216]

Also how do you make piston rings

[@edsheeran2345]

Awesome.

[@tareklakehal7713]

very good♥♥♥

[@rodrigodiego6304]

Thank you!

[@Khether0001]

I wonder why it's called "green" sand.

[@thermion7869]

As usual, brilliant!

[@5850terry]

Well done.

[@carneeki]

Lovely work!

[@AaronEngineering]

Hey Adam, I see you're a fan of Myfordboy too. He does some great work doesn't he? Cheers, Aaron.

[@kcraig51]

Wow....amazing!

[@antoninorusso8961]

spettacolare.

[@jackexperiments6790]

Wow

[@magpe75]

always a pro

[@cdickenson64]

The engine kind of works like a hit or miss, doesn't it?

[@myfordboy]

It's 8 cycle AND hit and miss. The timing only allow the engine to fire every 8 stroke instead of the usual 4. So it goes intake, compression. ignition, exhaust,exhaust,exhaust,exhaust exhaust. On top of that there is a govenor which cuts in when the engine reaches the required speed so the the engine does not fire that often.

[@aussiebevo103]

“ green sand “ haha. Looked awfully brown to me

[@av8ordavvee]

Parting powder not in an old sock! Anarchist !!! Just joking! What a beautiful casting!!!! Thanks for you videos!

[@herbiehusker1889]

What is parting power? It looks like talcum powder or something similar

[@maksmail]

2:38 partying powder

[@dogdooish]

Mother will be pissed when she finds the chair leg :)

[@choysum9030]

Build a ferrari engine.

[@BrunoPontoTxT]

Great work!! watched almost all of them :) can you make a video showing how to make an convex shape? llike this mirror... laser.physics.sunysb.edu/~wise/wise11/spring2001/reports/MountSinai/mirror2.jpg thanks

[@myfordboy]

It can be done like the one in this video ( but without the loose piece) kzbin.info/www/bejne/eqWVnqSirLKskLc

[@BrunoPontoTxT]

myfordboy Thank you, actually is very simple, i was struggling to think in a way for doing it xD

[@AndreaFromTokyo]

FAAAAKE The sand is totally not green! lol

[@hollowpoints9216]

How do you know how much aluminum to use?

[@myfordboy]

I do a full crucible and it's enough for the size of castings i make, You can also submerge the pattern in a full bucket of water and measure the water displaced to give the volume. Add more for gating.

[@MrSpeedholic]

what CAD are you using?

[@myfordboy]

ViaCad 2D 3D