The Bucket Foundry

[husaberg]

neat......After watch the vid i can see two things Greg is talented, as are you. I can also see why you get such a good finish with your composite mold Green and Shell clever.......

[Bert]

Thank you very much for sharing all of your hard work with us.

[husaberg]

To save clogging up the ESE thread i will put it here.

RE 2 stroke air cooled cylinder with Aprilia like porting
I guess i are over simplifying it.
but a simple male made out of a cut up say DKW125 or Sach MX cylinder

cut in half with the areas bogged up to accommodate the PV etc with the CO2 set sand core for the transfers and bore would that work? as any voids would become in effect alloy.
I guess the drafts and radius's might need a little extra work.

For Neil i have posted this before (somewhere) it is a neat mix of Tech and old school i love his and his contacts work.

http://flashbackfab.com/excelsior-pr...lsior-mock-up/
http://flashbackfab.com/excelsior-pr...ne-production/

[husaberg]

The head is easy, all my 350 heads have been cast at Thames. The cylinder? I've never cast an air cooled one, I've got the beginnings of patterns here to cast a 350 cylinder ( air cooled ) with modern porting inside but have never gone any further. Too busy dicking around with sleeves etc. I'm sure it would be not a big deal. The mould to make the sand mould ( outside ) would need to be steel I think and the core baked in shell sand. Or in this case lost wax system, maybe? A die is still needed to make the wax original anyway.
Surely a proper ( modern ) constructed 100 cc water cooled would be the go? Perhaps making it a two cylinder with vairable rotary valves.
If E85 were legal, then air cooled would be less of a problem. Internal liquid / vapor cooling.
Having the original core boxes for that cylinder ( you show in the picture ) would be a big help.

these old things oh i was planning on using them for kindling........

[Flettner]

Here is a sad looking 350 cylinder. The problem with using an original to copy from is the surface finish. You will need to polish the fins smooth, with no undulations as the taper is so slight that it takes very little of a blemish to hook up and break the sand copy ( mould ). Better off to build each fin layer by layer, that way its easy to access the surfaces as you build the pattern up. Note the gaps in the fins , these were always said to be there to aid cooling, crap, these are there to offer some support from sand fin to sand fin ( sand mould strength ). You just have to see things in reverse all the time, funny thing, I somtimes have trouble seeing things the right way round!

[Flettner]

Should find some cases for the sleeve cylinder in here somwhere.

[Flettner]

Possibly already shown this photo? The 360 cases ready to machine, heat treated to T6. right hand case is nearly finish machined now.

[F5 Dave]

. . .
Note the gaps in the fins , these were always said to be there to aid cooling, crap, these are there to offer some support from sand fin to sand fin ( sand mould strength ). You just have to see things in reverse all the time, funny thing, I somtimes have trouble seeing things the right way round!

I always thought they were for the rubber dampers but now you say it it is so obvious. Thanks for edumacating us.

[jasonu]

I always thought they were for the rubber dampers but now you say it it is so obvious. Thanks for edumacating us.

Maybe a case of double duty.

[Pumba]

http://www.trademe.co.nz/business-fa...-677592908.htm

[Flettner]

Here is a home foundry, 60L drum with rockwool lined inside. Burner is powered by Tellus and fueled by Ethanol ( with a hint of castor ). Crucible, ceramic type. Gravity is the fuel pump.

[Flettner]

Ready to pour, safety is my middle name! Fire is from magnesium powder poured onto the risers

[Flettner]

The finished item



Ready to fly

[husaberg]

Rob posted this by mistake kind off.........

[husaberg]

........

Neil the bridges on the Cylinder and head fining Is it because it is a 4 piece mold, and it makes it easier to make a neat join? or to support the mold? or both?