TALLY HO CAPSTAN PART3

This begins with the sodium silicate cores that will be added to the first successful mold for the Tally Ho capstan. I want to thank my friends who, without their help, would have made for a much more challenging time getting this mold made.
James T. Kilroy of Vicksburg
Eddie Wilson of Madison
Sean Thompson of Jackson
have each been able to make multiple trips out to Windy Hill Foundry to help make this project.
I want to also thank a past customer of mine and good friend, Eric McDonald for coming out and bringing Walt Grayson of WJTV. Walt shot some video that some of you are now familiar with that gave a sneak peak into this trial pour.
• Focused on Mississippi...
www.patreon.co...

[@scotts.2624]

"I pray they were only closer so I could get my hands on them" That line has made my day.

[@Tim_griswold]

Mine too 🇨🇦

[@larsrodbok1285]

Clarke is my hero!

[@Bamamarama]

Had me craking up.

[@The1nsane1]

For a second there I thought you were going all fundamentalist, instead you went all pugilist.

[@TomSramekJr]

Talk about thoughts and prayers.... ;-)

[@billmeldrum2509]

This series has more drama than 80% of what’s on TV.🇨🇦

[@KeefyKat]

Hitchcock's "High Anxiety" should have had a moldmaking scene!

[@johnsherborne3245]

You are boasting, our tv is worse!

[@royreynolds108]

AMEN!

[@OldIronShops]

indeed it is lol

[@heinvosloo45]

I never thought that getting the mould ready could cause so much stress! I had to take some whiskey to calm my nerves! And I was only watching.. I am looking forward to next week's video. Good luck! Hein Vosloo South Africa.

[@Alltakenbla]

Hope the whisky was good!

[@rationit]

I nearly had an asthma attack .

[@idontthinkso666]

Whiskey is great medicine.

[@nagualdesign]

​@@Alltakenbla That's whiskey with an _e,_ so probably not as good as proper Scotch whisky. 😉

[@kennethhughesjr.1780]

I've been following Tally Ho from the beginning. I'd never been exposed to foundry work before and I am gratefull to you for these videos showing what's involved in it. The skills and professionalism you put in to your work is inspiring and I will be following you from now on. With respect.

[@webbtrekker534]

Same here for both.

[@Mark_Bridges]

@@webbtrekker534 The bronze floors, knees and perhaps other fittings for Tally Ho were cast in bronze and shown on a bunch of Leo's videos. So we've seen the casting process before. Casting the capstan is a bigger and more complex job so is a level up from the simple knees we've seen before, so I agree this is still very interesting.

[@webbtrekker534]

@@Mark_Bridges You are absolutely correct. I just didn't collate that. That is what happens when you are 78 years old some times. My mind says it is only 22 years old. My body has a counter argument. 😁

[@ronbuckner8179]

Same here! Tally Ho is a work in progress. It’s a going concern . This is probably NOT your average job, and I’ll bet this is not as profitable a job as you’d like, but I doubt you’ve ever had as much exposure as this job is giving you, hopefully it’s working out for you.

[@Ibh111142]

Why on earth would anyone want to criticise what is a work of art!!! I think it’s bloody brilliant

[@Ibh111142]

@@billhamilton2366 try again didn’t even crack a smile

[@obsidianjane4413]

Because the Internets are full of mean people that don't know what they don't know.

[@johnshepherd4842]

Gentlemen, Its a pleasure to see your efforts, which are commendable, and most sensible people are appreciative of these videos, disregard idiots, the majority thank you, kind regards, from the UK

[@porkchop955]

Ignore the keyboard warriors who have probably never even made their own bed let alone a complex casting that you are attempting. You dedication to perfection is commendable. Thank you very much for sharing your skills with the world.

[@porkchop955]

@@billhamilton2366 And where can we view your dedication and perfection?

[@obsidianjane4413]

@@billhamilton2366 So what?

[@bobh64]

Having done sand casting in 80's trade school, it is very nice to see people still doing this valuable art form.

[@johnmonkey1874]

I had to give a thumbs up for the "I'm praying for them" comment.

[@Bamamarama]

Who needs reality television, when you have Windy Hill Foundry? Edge of my seat the whole time. Great work as always, looking forward to the next go around.

[@zzanatos2001]

That is a challenging component to cast, but in the end it will all be worth it. The Tally Ho is a masterpiece, and this capstan will be the crowning touch that people will admire for the next 100+ years.

[@Edward-tz7xz]

I have not been exposed to the intricacies of making large castings and am thoroughly enjoying these videos. The process is far more complex than I ever imagined requiring the supreme skill and knowledge of an expert. Thank you so much for taking the time to videocast this process for us.

[@chrisclarke3670]

You guys are busting your butts trying to pour a very difficult job. My hats off to you! Wishing you much success on the next pour.

[@goboyz8016]

Don't understand people with negative comments. You guys are a bunch of great human beings and for anyone to put your or your work down must be very lonely and bored. Great work and please don't let those idiots get you down. Keep up the great work and most of us all know how hard it is to do what you do.

[@barriewright2857]

I like that " those guys behind the keyboard are ten foot tall in their mom's basement " 😂🤣😂🤣😂🤣. And keep what you're doing for me it's a education and informative, and casting is not easy, especially the pattern making and then marking the mould from the pattern, it looks hard but i like the way you per saver 👍🏿.

[@bin_chicken80]

Forget about the people who doubt you Clarke. Very close this time and I'm sure you'll finish the job and get a nice casting. Great to see you have some good friends out there to help you.

[@ChuckOso4483]

A one-off casting is an incredible feat, let alone one of this size. Don't let keyboard warriors get to you. You're work is exceptional and I'm on edge watching every minute! Can't wait to see you get it done right!

[@paulciampa]

I'm thankful you're doing this work and making a video record you are keeping old things alive. I can only imagine how many small foundries were in America that did these projects when things were made in America. God Bless

[@lynmcclure9156]

Thank you so much for sharing the skills that are rapidly being lost in our world. As a tradesman all my life I can appreciate all the work and craftsmanship required from ALL those involved in the restoration of Tally Ho. Taking the time to share through modern media adds countless hours to your labors. IT IS APPRECIATED. Do not let the keyboard jockeys discourage your effort to share these skills with others. There are more viewers that appreciate your efforts than the few that critique from their sofas and TV tray. We out here prefer to turn tools and just don't type often. While our world has embraced the Arts and Entertainment those that are sharing the INDUSTRIAL ARTS are providing a positive input to Society. THANK YOU FOR SHARING.

[@william6526]

I was hoping this pour would be the one but now I get to watch this process again. You put an amazing amount of work into this job and I hope you put your name on the finished piece once it's finished. You deserve the recognition and the praise from the generations of people who will see this work of art in the future when we are all no longer around. Please put who built this piece somewhere where it can be seen.

[@jimrobcoyle]

Woo-hoo! The project is coming together! Tally Ho! ❤

[@roberthumphrey1304]

I appreciate your efforts to keep an old process alive and educate people abou😮t what the old timers did. This is a relatively small casting compared what they did building steam engines in the 1800s. I have a hard time imaging how they handled the big parts of over 500 pounds. Cudos to the volunteers that are willing to help you with this endeavor and thank you for persistence to see this through.

[@markmatt9174]

I follow a Indian foundry & recently watched them pouring some big flywheels in sand piles on the floors. Guessing 2500 lbs plus per. Had a 3 day cool down for them.😊

[@johanhellings6580]

What an accomplishment !!! Had no idea this is so complex to poor. Great job !!! Looking forward to the next attempt. Cheers from Belgium !

[@geneard639]

Considering this is the largest pour that I've seen you've ever tried, its obviously a tad bit beyond the physical capabilities of your shop? Having a first attempt to come out that good? OUTSTANDING! I was expecting to see half a blobby shape to fall out.

[@byrnejr]

Haters have to hate! You just keep doing what your doing! Love the channel,better then anything on TV. ❤

[@tglackin2411]

Found myself holding my breath a number of times during the video.

[@johnb6763]

Thanks!!!!!!! I have been keeping track of the Tally Ho since it started. It is great to see all the people who work so hard to get this thing done. BTW Tally Ho has had a few real hard days......and they worked it out. Think hot lead..... :)

[@jameshamre8778]

The disconnected conversations are absolutely hilarious! What a great time for friends, and video about the pattern pour!

[@arthurjacobs9330]

Bless your heart bud, dealing with folks that don't appreciate hard work and skill. I guess it easy to be a tough know it all when you don't have to look a man in the eye. Good luck with this all your other projects. I love seeing master craftsmen at work.

[@rusedorange]

The most frustrating, excruciating, process I've ever witnessed. I truly admire your art, and devotion.

[@NimmoJamie]

It's a truly great thing you are doing for Tally Ho and Leo. I try to imagine the foundry back in England over 100 years ago where the capstan would have been originally cast and compare it with the Windy Hill Foundry over in Mississippi today. I hope they too had such a wonderful loyal group of gentlemen to help out.

[@timthompson1940]

55 years ago I lied my age to get a job in a grey iron foundry. Wish I could help.

[@davidgoulden586]

Very well done, for you and your friends to donate your Saturdays to make this casting. Pay no attention to any adverse comments, your doing a great job. Best Regards from the U.K.

[@bokluge3855]

Having high standards , knowing the potential and committing to great quality is not an easy road. Work like this sets the standard for all others to strive to achieve. Thank you for sharing what takes a lifetime to master .

[@dannyvanstraelen3273]

It's an art form that got my deepest respect, and the community spirit that goes along, I really love it. And I'm glad you're showing the up and downs and the rethinking it takes to pull this thing off. Don't let the keyboard heroes spoil you day, you got a lot of people's deepened respect.

[@cribbsprojects]

I think you're doing a great job. The guys being there for moral suport is good too. Great team. Not an easy cast... Loking forward to seeing more. Every part of this boat has a story to it and your part is a great addition...

[@brutusbarnabus8098]

It is important in life to remember that the sun doesn’t rise and set over the crack of your ass. When you put something out for public consumption you have to be prepared to take the good with the bad. I am enjoying the hell out of your videos as are 99% of the other viewers. Not shabby. You are genX and are supposed to have thick skin unlike today’s perpetually offended generations. C’mon now. Carry on and ignore the noise, good sir. 😎👍🏻

[@andywithers592]

Great teamwork. Great progress. Kieth definitely needs to build that jib crane now to chuck this piece. Keep up the good work. All the best from Switzerland.

[@plakor6133]

Well if you have to have a specialty project, you sure picked the right one!

[@meldert]

So interesting to see both the ups and downs of this process. Great idea to sell this first pour as a unique memorabilia from the Tally ho project, now just get Leo to annouce it on his channel too! You guys deserve a bidding war! ;) :)

[@kaydog2008]

Stil good work!!!!!! I look at all failers as a learning experience and a step closer to getting it right. No matter how it's done. The cheapest scrap way or a little more then I wanted to spend, But alway's the cheap way working with what you have. Give it all you have for the next pour.😎👍👍

[@boossersgarage3239]

I like all the safety gear but after watching those guys in Pakistan wearing sandals and pajamas doing the same thing you look a bit overdressed. LOL

[@WreckDiver99]

The more I watch, the more I can understand the costs incurred to have you do custom molding for people. Dave did an AMAZING job on that pattern and core boxes, and it still is a tough mold and pour. You're doing AMAZING! As for getting older? Trust me, I'm 1 year behind you Clark, and I'm not in any where near the physical capability any longer. Between a shot lower back (Diving 120lbs of doubles (SCUBA Tanks) with two deco bottles on the waist for a few years), and 2 herniated discs in my neck (30 year old injury)...I don't think I could lift those molds. Props to you! You're doing an amazing job.

[@waynes.3380]

I appreciate your commitment to excellence for products going out of your shop.👍

[@pipedreamz66]

I have never been so intent on watching something get built, as what you and your team, are in the process of doing. I only hope, that America is taking notice of what must be done to get to the final process, of restoring History....Tally Ho is Blessed to have you and your friend's, working so hard to make a dream come true...you are an amazing craftsman Sir!

[@robertmcausland4916]

I appreciate you doing these videos and for helping Tally Ho with this project. You're a good man and you have some great friends helping you out.

[@CJLeTeff]

No way trying to be a know it all here but I think that strap is torquing your mold breaking sand loose.

[@TheRealMotoNut]

Not only is this a lost art but most people don’t even understand how anything is made. I wish there was a highschool class that just thought how things work, how things are made and the basics of manufacturing processes, along with basic mechanics. I took welding in college 30+ years ago and have been restoring Vintage motorcycles for 40 years. I have always been obsessed with how things in the world work and how things are made. I can’t go anywhere without looking at everything around me and visualizing how each thing was made. I look at every weld, casting, forging etc and visualize it being made. I can look at just about anything and know how it was made. It borderlines on OCD but at least I don’t wonder around completely ignorant of how anything is made or constructed. At least we have KZbin today.

[@danielmccann4055]

Amazing effort Guys. for me The Tally Ho project is an icon for the last dying days of the Republic. Respect.

[@bvalt1]

Im also 57 and a carpenter who uses help whenever I can get it, you guys are awesome, and knowing your limits is the most important thing you can ever learn. Took me several injuries in my lat 40's to learn that, can't wait to see the final casting!!

[@NOELTM]

I came here from Tally Ho. I am amazed at the skill and complexity of making the capstan! Bravo to you for taking on such a task and to your friends for making their time, and it seems some squashed fingers, available too.🙂

[@jackterry7664]

I just watched keith Rucker do some machining on the capstan casting for a ring gear.

[@pfalzgraf7527]

Fascinating and captivating videos! Thanks for all of this! Great work with the equipment you have! I really love the good work. All the Best!

[@generessler6282]

Brilliant. Thanks for keeping us up to date. Don't want to jinx it, but looks like next time is the real deal. I'm deeply impressed by your patience and dedication to quality.

[@drop_dtuned6167]

Wow! Seeing how the core box works, this episode put it all together for me. Super fantastic!

[@CHICOB4261]

Clark, thank you for your hard work and laboring so diligently to produce something that will undoubtedly be a work of art worthy of being mounted on the Tally Ho. I know there are many ways that this could have been done but you are the one who is doing this one. I would invite like minded individuals to attempt what you undoubtedly will achieve. Don’t be discouraged by those who are criticizing your efforts they to are busy producing much of nothing!😜 carry on sir!

[@philipmeads9333]

Hey 99.9% of people really appreciate you taking the time to show us the process - thanks for giving us an insight !

[@johnm8939]

You guys do amazing work. Not an easy process! The work that goes into something like this is crazy. I’m sure there aren’t many companies doing this kind of work anymore. I learned a lot from the videos!

[@Vindsong]

Experience, skills, talent and quite a dose of pure strenght💪🏻Thoroughly impressed. Great job!

[@oddduckfoundry8223]

Oh so close! I sympathize, the largest cast iron casting I have done so far was a 16" diameter headlight bezel for a locomotive tender light. 19" steel flask, took most of my sand and a helper to split and move the mold off the bench. Thank God it came out first try! Keep up the good work, you've got the process worked out. Been watching the whole story since Keith took the original apart. Trying to figure out how I would do it if it were me, your sand is waaaay better than mine.

[@brianross1488]

Looks like a super difficult project. Keep up the great work. Can't wait to see the finished project. Im sure Leo and everyone of the Tally Ho fans are rooting for you.

[@roytally8329]

Yes, and I am one of them! Keep at it, you've got this.

[@WildmanTech]

I really appreciate your effort on the Tally Ho.

[@tomviti544]

calm and persistant...craftmanship . SV TALLY HO is being built by some talented artists and the work you all are doing will complements the rest. thank you. tev

[@creageous]

I love watching this process. It's fascinating and you really learn a lot more by seeing what can go wrong. Watching edits where all goes well leaves you with a false sense of ease. Good luck with the next one. Looks like you got it, tho. Great stuff!

[@sejofgville]

Now I finally understand how the cores work! Yes, I could have looked for other videos to show how they work but I was just waiting to see how it worked for this casting. Great work!

[@markchodroff250]

Wow ! Like they say it’s 90% preparation, the job is very big and you need a lot of patience, knowing that even after days of work you may need to do,it all again! God bless you and your helpers it’s a true art and it’s dangerous also !

[@ericborgstrom2588]

I come to the Windy Hill Foundry channel by way of Tally Ho, which I've been following since the beginning. I feel compelled to comment, which I seldom do, to express my appreciation and amazement at the amount of effort required to provide a new capstan for Tally Ho. It gives me a real appreciation for the skills (and the ability to withstand constant disappointment) required. Thank you for all your effort!

[@JH-qv3xv]

Thanks and looking forward to next Sunday.

[@88TRUNKBACK]

Keep going your a fine craftsman and artisan, as for the basement engineers old Frank said it best “some people get their kicks stomping on a dream”

[@American_Jeeper]

Clarke, the amount of detail that goes into this casting is incredible, and it really makes me admire the foundry workers who cast the original capstan 114 years ago. It's a shame you weren't able to take the original, broken capstan and melt it down to recast it. It's also a shame that people find it easier to be nasty than nice. I'm looking forward to the next video, thanks for doing this.

[@pokerpig9069]

If I ever find myself in your neck of the woods, I’m buying you all a beer or two. Great job, great video. Real people.

[@sgibbons77]

I love that you show the failures as well as the successes on these special jobs. Makes me feel better about how often my own (much smaller) castings go wrong, and I rejoice when you do finally have success!

[@allobject]

even just watching the clip(s) makes me holding my breath and increasing my heartbeat. Great work! ...and very balanced comments at the end. Thank you!

[@Mr572u]

We did a lot of foundry in metal shop in high school. Our cope and drag was made of steel and had a big alignment pin on each end. The sides of the form were irregular so it held the sand from ever falling out. We had what looked like, a wooden dumbbell to compress the dirt. Most of our failures came from getting the molten aluminum too hot, or the sand too moist. That and removing all the slag before pouring. It was fun to do the projects we did and try to get better each time. My instructor was great at it. Herman Fitzgerald was his name. Milby High School, Houston, Texas. 1967. Yeah, I’ve been around a while!😊

[@Jason-xb3jh]

Thank you for keeping such an awesome trade/craft alive. You guys are the fabric that makes this such a great Country! 👍✨🇺🇸

[@jonessmith2068]

I am totally impressed by all the skill and hard labor that goes into metal foundry castings! Thanks for a view into a world many never see its very interesting and I can see frustrating at the same time if the sand form does not work out just right.

[@TomokosEnterprize]

I'm sure glad this could be fail into a keeper with a story behind it. I cast/pour silver on a far smaller scale so this 3 part is of particularly interesting for me. You mentioned Petrobond. I have been saving the burnt sand ever since I started this gig. Do you reclaim the burnt stand and with what medium do you use. I have gotten some petro that was far too dry and was able to fix it with mineral oil. Will that work for the burnt petro ? Great post today, I really enjoyed this and will be here for the next instal. All the best to you and all the fellas that came to help. You have good people around you.

[@RRINTHESHOP]

Nice getting progress. Good to see James. I hope the next one is good.

[@rinzler6757]

Really enjoying these videos. Very interesting to see how this happens. Thank you for the extra work that allows us to see it.

[@giles-df9yu]

I watch a lot of the funny Pakistan guys pouring and they actually do a good job.. you need to watch some of their work. However that was lots better than the first attempt.. you stomping the sand with bare feet would be a side buster. Ha haha good job

[@trevelynbrown4444]

I'm 57 Retired military plus 20 years making car parts . I would never try and tell you how to pour cast iron. Why? I am not even a novice . I stay in my specialty fields . Yours is not one . Keep up the great work . I respect you for not sending out substandard work . I know you will knock it out of the park .

[@aserta]

One thing i would've changed is i would've added a few handle holds (kinda like drawer pullers) on the sides of the octagons. For example, at 22:25, they would've come in handy for alignment. I guess this being a super limited run, the're no need for them, but on most of the biggun's i've seen, they put those features for ease of use. Awesome work regardless!

[@markl8111]

I enjoy the workmanship, experience. There aren't that many people who retain these skills.

[@bruceadler-9410]

Adding 210 grams of sodium silicate to 3000 grams of sand is only 6.5% by weight. You need to add 226 grams of sodium silicate if you want the final result to be 7% by weight. 226/3226 = 7%

[@TheJohndeere466]

3000*.07 =210

[@bruceadler-9410]

@@TheJohndeere466Yes, I know that. But if the goal was a 50/50 mixture you wouldn't add 1500 grams of Na2Si3, you would add 3000 grams of Na2Si3. So the final proportions of the mixture he created is 210/3210 = 6.5% Na2Si3 and 3000/3210 = 93.5% SiO2 (sand). It is not a 7% mixture by weight of Na2Si3 and sand. It's only a 6.5% mixture.

[@snappingbear]

​@@bruceadler-9410Yes, you're exactly right. The percentage of something is always based on the total (3000+226), not the subtotal (3000).

[@shuanf7687]

If it were easy everyone would be doing it. You have the knowledge that many craftsman would envy. I appreciate you sharing with us some insight into your trade. Keep up the good work!!

[@WoodenBoatBen]

It’s amazing! Anyone criticizing you is out of their mind.

[@krockpotbroccoli65]

I can't imagine the sheer immensity of the facility that produced these things back in the day. Keep in mind that this is just one piece of the total assembly that makes up the capstan. Presumably, these were mass-produced items. Absolutely mind boggling.

[@JohnfromEngland]

Better luck next time and I am enjoying watching all the processes John from England 👍

[@martynbuzzing3327]

If anyone can, you'll be the one to produce a brilliant capstan top. Well done you and your team..😊

[@brianpesci]

Certainly a large, complicated piece, these are very interesting to see the very delicate parts of getting the casting just right. My neighbors once had a foundry across the street from us in Lackawanna until they changed the zoning laws. So much of that industry of working with steel and iron, made this entire part of the State of New York a very critical part of the entire WWII war effort. You're keeping a disappearing art form alive.

[@Rugbyman269]

As an Englishman that has been watching the progress of tally ho , I'm astonished that there are craftsmen like yourselves that are prepared to do this kind of work presumably knowing you won't make a profit from it .

[@henrikstenlund5385]

Wow, now I can breathe again. Good job in a very challenging task

[@paulputnam2305]

Way to go. That was awesomeness extreme. Thank You for sharing your wonderful life with us. What a great group of caring, real people. Much Love and Hugs

[@singendertanz5075]

with due respect - if the sand of this foundery will always so bad prepared the waste will be often in the same grade...! It was even looking on the video visible everytime when clearing the faces...

[@axiom666]

Very interesting work, I admire your patience, well done. From the UK.

[@samrodian919]

I worked in a unit that was in a foundry yard for four years here in England. I was fascinated by the processes of moulding and casting iron. I saw first hand day after day the very hard graft that these men put in and the dedication of their work into making successful castings first time. And they had about 60 men working there, you are on your own apart from your wife six days a week and with your mates on a Saturday. And I think you turn out fantastic work sir.

[@stevewoodard527]

I spent over 40 years working with aerospace foundries to produce structural castings for our gas turbine engines -- Haley, Hitchcock, Wellman, Ohio Aluminum and quite a few others. Making an object that looks like a casting is a necessary first step, but the fun comes when you start x-raying and using penetrant to detect flaws. Either way, it's interesting to see just how little is really necessary to make a casting that doesn't have to pass NDT requirements. Hang in there!

[@mikebuckley5171]

Thank you for showing your fantastic work! The difference between craft and art is small and you are hard up against it. The people who don’t respect your work don’t deserve any. Keep it up.

[@paulstuard7988]

getting better every time. I believe you will get it done. you are a true artist at your work.

[@stuartlast8156]

You had me sitting on the edge of my seat there at times !! Well done, thanks for sharing with us 👍

[@manmachinemake3708]

Not sure if it's been mentioned before but what about screw on latches to hold all the boxes together while flipping around ? I have to imagine the ratchet strap, not only being cumbersom, causes the sides to pull in when tightening it down.