“New” and Easier Way to Cast Aluminum -- Molasses-Bonded Sand Part 1

This is an introduction to molasses-bonded sand casting. This technique is well suited to the backyard foundry-person or the do-it-yourselfer. It is both easier to get started and easier to do than many other casting technologies because the ingredients are easy to find and processing is simple. This process is common in East Asia but virtually unknown in the West. Many fine videos demonstrate this process but do not explain it. This is the first in the series of videos that will explain the process in depth.

[@richardlawless3989]

Brilliant, simple communication! Thank you.

[@spacee3249]

This video is worth it's weight in gold

[@stefannovolaniste9661]

Bravo and thanks ♥

[@davidwimberley3267]

Thanks.

[@RustyRusselsThoughtfulLi-xm2jj]

Useful, simple, and to the point. Very good. Tyvm.

[@davidwimberley3267]

I expect to make more videos this fall. Thanks.

[@andrewdean4304]

Molasses moulding sand also contains bentonite clay the same as green sand, but instead of water molasses is used. We use it lots in the foundry, it’s Ideal for intricate patterns

[@curtisballer688]

So you can’t just use sand it has to have the clay in it also?

[@adityasuresh6607]

So how strong is it under tremendous hydrostatic pressure of molten metal like cast iron ,I am talking about 100 pounds(45kg) or so ,green sand changed width ,or should I try sand mixed plaster of Paris mold now.

[@andrewdean4304]

@@adityasuresh6607 it's fine under pressure, as long as it's sufficiently rammed. It also hardens instantly with the heat from the metal going in the mould

[@adityasuresh6607]

@@andrewdean4304 ok

[@juliusbeukes761]

The ratios is, 4% bentonite to the weight of the silica sand, the molasses is also 2-5% to the weight of the sand and last is the water, it should be between 2-9% by the weight of the total mixture.

[@gedhuffadine1873]

Just subbed really enjoyed , got a couple of cassting projects in the planning. Hi from England.

[@davidwimberley3267]

Thanks. I need to get back on the ball.

[@85rocco]

Thanks, I've been curious about the sand used in those videos from Pakistan. Looking forward to the rest of videos in this series.

[@grouchosgarage6477]

Thanks. I hope to do another soon.

[@scopeboy66]

Wow thank you I never knew they used molasses I have tried the oil and clay and got some horrible castings out of it. Your casting looks so nice. Thank you I will try the molasses now

[@chrisatkins5931]

Thanks again David for the extra information re brass casting. I’ve got bentonite clay( kitty litter) Molasses ( from animal feed place or supermarket) and sand I’ll use my trusted coffee grinder sieve through fine mesh to get it fine as I can. Nothing to loose cast and cast again.

[@davidwimberley3267]

Of course things get a lot more complex in a commercial foundry. First of all, there are two kinds of bentonite, southern, and western. Also, when you use clay to bond sand, the usual procedure is to mull the sand. That means that the sand and the wetted clay are intimately connected beyond just mixing them. Each grain of sand is supposed to be coated by the adhesive clay. That may be difficult to achieve at home. Of course all of this doesn't mean you can't find a way to make it work. Your recipe and procedure do not have to be optimized because you're not in a commercial setting.

[@johnpeters4984]

Very interesting, a new angle to a old process. Thank you.

[@davidwimberley3267]

Thanks for your kind words. I hope to have a new video soon.

[@enriquegrajedacazarez1228]

Thanks for the video .. I always thought that they were using molases to bind thier sand... Great that you shared a mix formula... Keep videos coming

[@davidwimberley3267]

Thanks for the encouragement. I will try to get back to making videos.

[@s.hutton2100]

Looking forward to seeing upcoming videos.

[@davidwimberley3267]

Thanks. I need to get back into it.

[@curtisballer688]

Clear direction! Enjoyed thx

[@davidwimberley3267]

Thanks. Hope to have another video in the next few months.

[@levi_madeley]

Fantastic thank you!

[@davidwimberley3267]

I hope to have new stuff soon. Thanks.

[@user-ui7zj7xi9x]

Thanks. Simplicity is always good. You can always go more professional and production minded but if you can not master the basics you are barking up the wrong tree.

[@davidwimberley3267]

Well said.

[@joshtonry4291]

Good information, thankyou

[@davidwimberley3267]

Thanks. I have a lot more to share, but haven't been able to get back to it yet.

[@bertyjustice4424]

great video , thanks for showing us

[@davidwimberley2510]

Thanks. I hope to post more soon.

[@davidwimberley2510]

Thanks for your comment.

[@Blaxmyth1953]

This is vidio gold! Thanks so much!

[@davidwimberley3267]

I knew this content was a rich vein, but good to hear it from others. Thanks.

[@yamabiru4553]

Good job!

[@davidwimberley2510]

Thanks. I hope to get back to it soon.

[@TheGospelAccordingToMarkyD]

Awesome.

[@davidwimberley3267]

So kind. I hope to get back into it this fall in the drier weather, and maybe with a cast to produce.

[@headstocktailstock]

Splendid video, I've allways used greensand or co2 & also petrobond [for plaques with fine lettering] & watching those pakistani foundrymen you can easily tell if they're using greensand or molasses sand by the way it slides down & cakes to the casting ,real craftsmen [& brave with bare feet!!] thanks for the formula I'll make some myself & follow your videos

[@davidwimberley2510]

Good luck with your projects.

[@headstocktailstock]

@@davidwimberley2510 Thank you David,keep up the interesting videos they're really good. Regards Graham.

[@Pablo-zz3tw]

Thanks

[@amgproject]

Thanks for sharing your casting experience . I cannot find molasses locally but I am eager to try that casting mix... I wonder if sugar syrup can be used instead of it?

[@davidwimberley3267]

This is a very interesting question and, unfortunately, although I thought it would be otherwise, a syrup made of sucrose, that is table sugar, will not substitute for molasses. If you live in the United States, molasses is going to be available almost anywhere. It's available in feed stores as well as grocery stores although the feed store stuff will have some preservatives.

[@chrisatkins5931]

What a clear and concise video. Thanks. Have you any tips on fine detail brass casting?

[@davidwimberley3267]

Thanks for the kind words. I'm sure there are many techniques for doing fine work. The principal ingredient is fine sand. I think I've seen some Indonesian jewelry making where they use sand bonded with both clay and molasses.

[@geeljireoomaar6140]

Brother I am watching your interesting videos in Africa. I want to ask you a question. I have seen sone Asian men casting skillet. They were not using sand. Instead, they were using a pre designed mold. It looked like to me graphite and clay. It is a pre set permanent mold. Do you have any idea what it is?

[@ideasytnow]

Wow, just now found this video.

[@davidwimberley3267]

I expect to post a new video very soon.

[@purvel]

Hey thanks for the video, I've been wondering what was up with their sand! My old brazier master used molasses as a mold wash but I never thought it could be used like this too. Never thought to use sugar, turmeric or ginger for parting compounds, would they work in regular greensand too you think? Or what makes them suitable here? Also looking forward to the rest of the series, I enjoyed the production and clear instructions a lot. Especially the text intermissions made it easy to rewind to a section I wanted to rewatch.

[@grouchosgarage6477]

Conventional parting or agricultural lime has a little silica in it so it should be used outside or with a respirator and I figured people would be likely to have sugar and a grinder or turmeric or inger and by extension, possibly some other herbs or spices if not those that would adequately work especially if you want to work indoors with children or whatever. Also, I constantly ram up molds so I can understand the sand better and I don't want to dilute my sand too much. I think regular parting which is usually just ground limestone or chalk which is also calcium carbonate, might make the sand a little more tired than some of these other party agents.

[@purvel]

​@@grouchosgarage6477 Thanks for the info! I will try some of your parting suggestions, powdered sugar seems like a pretty sweet alternative to talc or chalk ;)

[@shawnhryb146]

I'm looking to make Christmas ornaments out of molten aluminum. If I make a mold by pressing into the casting sand could I just pour the aluminum into the impression without having to use the top half of the cast?

[@davidwimberley3267]

It is better to have both sides, but you can do what you are proposing, but with somewhat sloppier results.

[@shawnhryb146]

@@davidwimberley3267 thank you for the advice

[@siddheshsuryavanshi202]

Sir, is it necessary to add water in molasses sand? And what is difference between molasses and bentonite sand?

[@davidwimberley2510]

You definitely don't add water. You have to allow some of the water that was in the Molasses to evaporate before it is a workable consistency. If the sand dries out to the point where it's not workable then water has to be added, but in order for it to be workable there will always be less water than there was originally in the molasses itself. It's an entirely different approach than a bentonite- or clay-bonded sand.

[@siddheshsuryavanshi202]

@@davidwimberley2510 thanks

[@WallaceLivingFree]

gooday mate. As a fellow YT video maker, I know the following is easier said than done, I love your natural comment at the end of this video, your natural voice is great, if you learn to "speak naturally" can you please tell me how to do it , cheers mate, love your channel

[@grouchosgarage6477]

Thank you very much for your kind words, but they come as a bit of a shock, frankly. I'm going to try not using a script next time and see what happens. I'll be sure to check out your channel.

[@WallaceLivingFree]

@@grouchosgarage6477 Hey Mate your natural spontaneous voice is great, as a struggling YTuber I really struggle in my voice on the vids , cheers mate

[@grouchosgarage6477]

@@WallaceLivingFree I don't think I can tell you much. I'm not entirely happy with my voice because it seems to have what I call the whiny San Francisco Bay Area twang of my youth, but I do naturally tend to resonate in my head, and I had a choir director try to recruit me in middle age so maybe I've got something. I did a fair amount of coral singing as a kid, and I can't say that I'm unhappy with the voice I was given. On the other hand, content is king, and you seem to have mastery of your content. I did not have any negative thoughts about your voice, watching your video. On the other hand you might want to have a look at the highly successful Project Farm KZbin channel. This guy is not blessed with a stentorian voice, but as I said, content is king and he does a wonderful job. During the last Christmas season, I watched some stuff about Icelandic midwinter legends and traditions. I think the narrator was a professional actor. In any event he was good, and it really added to the video, but it's not necessary to have that kind of voice quality to do the kinds of videos we do. By the way I looked at your salting meat video, and interestingly, I gave up meat completely a few years ago and as my blood pressure is starting to rise, I am now starting to live without salt so we are on opposite sides of the meat + salt divide. If you were really concerned about improving your vocal quality, you might try a vocal coach, but it's hard for me to imagine that that would be necessary. I know Garrison Keillor wanted to sing so he took voice lessons and muscled his way into the music on his show, and over time, showed significant improvement. Of course his speaking voice was good already, but he really improved his singing voice. Best of luck.

[@WallaceLivingFree]

@@grouchosgarage6477 Thanks very much for your reply , cheers stay positive and happy, mate

[@grouchosgarage6477]

@@WallaceLivingFree And the same to you

[@jeronimomod156]

Will playground sandbags work?

[@grouchosgarage6477]

The first step would be to make sure that it's fine enough to give you the sort of detail you're looking for. After that it's a matter of trial and error, but most sands will work well enough.

[@fucjape2]

I gave it a try but the sand just falls through the mould I think they another ingredient i won't stop using green sand, in looking into to this technique more hi see they use wood alcohol and burn it to the harden the mould

[@davidwimberley2510]

The sand has to be fairly dry, so, when squeezed it does not leave much on the palm.

[@geoffreyrichardson6540]

@@davidwimberley2510 Your an old fool that wouldn't haven't got clue what your doing

[@davidwimberley2510]

@@geoffreyrichardson6540 Thanks for your insightful comment.

[@stevesrt8]

interesting method. would this be suitable for brass or copper? i'm sub number 3

[@davidwimberley2510]

It is used for cast iron so it could probably be used for copper alloys.

[@kartikrana8347]

Sir how to make brass casting green sand

[@fucjape2]

Use 10% extra fine sand 100 grain or higher and 1.5% fine bentonite you will have a perfect mould,

[@geeljireoomaar6140]

Thanks! What kind of molasses do you use?

[@davidwimberley3267]

Any kind of molasses bought at a grocery store or a feed store.

[@andreweyo-ita4970]

TONY STARK WAS ABLE TO BUILD THIS IN A CAVE...WITH A BOX OF SCRAPS

[@marjon1703]

And may the Swarf be with you always.

[@davidwimberley3267]

Thank you. I think it will be.

[@TEKKKNO]

Just i came directly from the pakistani video and i was think its borned oil ar first

[@davidwimberley2510]

One of the videos explicitly shows preparation of the sand with molasses and nothing else. Thanks for your comment.