Casting metal....

I know I am opening up a can here, but here it goes......

I have been looking into casting small parts. I have a need for a brass piece first as I have lost an irreplacable part from a light I am restoring.

Lucky for me there are 2 on each light and I have 2 lights.

I have plans for some aluminum pieces if I can be succesful with it.


So has any one done it ? Any tips or tricks.

And yes I know i'm crazy, live with it, I do.

Do you have a local manufacturing jeweler or horologist with a lost wax set up?

Don't know. There probably is, but I really don't want to wast time on finding someone to do it for me. My dad told me about a place that does, so I have a backup plan.
I have the capability and drive to do it myself. Plus it will be another thing I know how to do. I seem to have started a collection of metal working processes. Just another outlet for the ideas in my head.

If it works out as planned, I have some commando bits I'm going to produce.

Think brass covers, I have had a few requests recently.

lookie here

http://www.youtube.com/results?search_q ... pKOtqnaneY

Good link, Hobot, I was suggesting he have a look at how its done 1st,`cause explosions of molten metal can sting a bit..

Find the scrap to melt then figure out the melting pot fuel type and construction then figure out the mold and have at it. Don't lean over a pot of molten metal with sweat dripping into it or can explode drops of molten metal on ya. Coming up with secure hooking griping lifting pouring tools will take some thought especially if single handed. There's a way to melt using charcoal and hair blower or leaf blower depending on scale of melt. Sand, plaster or wood or metal molds are common.

Brass melts at a MUCH higher temp than aluminium.
Al can be done on an electric or gas stove, if you work at it, for small items.
Brass requires a gas or better furnace. And if it gets too hot can burn the zinc out of it, requires considerable expertise.

Getting the sand or hi-temp plaster to do the casting into also needs some expertise, is there a local supply company that can give you a guide. ?

Are there any art groups nearby that do bronze casting - maybe you can do the prep work for lost wax casting, and get them to pour some brass into them ??

I have done lost wax aluminum casting in sand and investment. I make all the fuel injection manifolds using the investment- wax process.
Bronze requires more heat and a setup that I don't have. Jim

I've finally cast brass. It was a lot easier than I expected and the flowerpot furnace melted it with ease. So for everyone who's asked me, the question is finally answered... Yes! the flowerpot furnace can melt brass!

Click to expand...

http://www.backyardmetalcasting.com/brasscasting01.html

http://www.google.com/#hl=en&sugexp=les ... 39&bih=600

You could check out the Britten video wherein Jon does a homecast set of crankcases, he used to do his own bespoke household castings of doorhandles, taps [fawcets] & the like..

Don't know if this idea has progressed any.
Something else that occurred to me is that train/rail revival societies are pretty keen casters of metal, brass and iron in particular. They are everywhere ! May be worth making their acquaintance, rather than setting up for only a small quantity of castings.

Something else to be considered is shrinkage.
Below is a casting of an ES2 tappet inspection cover - the originals are pressed steel, and surprisingly difficult to find (souvenired for the badge ?). Did a few alloy replacements a while back - this one is a reject, someone (me !) drilled a hole too far up to look right (fits though). This is the view of the back of it, obviously.

Note how the actual holes are so far off the hole impressions - this is how much alloy can shrink in the casting. This is about 4" long, sandcast. Pattern has to allow for this shrinkage.
(The light copper coat is because was going to chrome it).