The Unofficial Mamod and Other Steam Forum

xlchainsaw · Posted: Wed May 14, 2008 12:39 pm Post subject: diy die casting

i found these vids on you tube. im currently giving it a go

my plan equals wheels and lots of them. other ideas???

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Nick · Posted: Wed May 14, 2008 1:04 pm Post subject:

What is your plan for melting the lead?

I have two melters from Lee:

http://www.leeprecision.com/cgi/c...3.4092=/html/catalog/melters.html

I would highly recommend one with a spout to save future headaches.

I make my own bullets and this guy included some very important tips.

xlchainsaw · Posted: Wed May 14, 2008 1:10 pm Post subject:

actually im going to use aluminium. the molding process i really found interesting. im awaiting my molds to dry out and then ......blowlamps at the ready,forge fired up..

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difficult things done straight away...the impossible takes me a little longer

Nick · Posted: Wed May 14, 2008 1:13 pm Post subject:

How much more heat do you need for aluminum than lead?

xlchainsaw · Posted: Wed May 14, 2008 1:22 pm Post subject:

Nick · Posted: Wed May 14, 2008 1:31 pm Post subject:

Is there anything you can use for removing impurites from aluminum? (I use Lee's beeswax for lead)

Does the paint off the cans just float to the top?

Make sure you have the mold warm before you pour it, otherwise there will be visible cracks or layers.

Also, make sure you smoke the mold like the guy showed, I just use some matches instead of a candle.

I am very interested in seeing a picture of your setup.

xlchainsaw · Posted: Wed May 14, 2008 1:47 pm Post subject:

we are very excited also. no flux is required although some hint about it.

there is a lot of scud from the cans ,so you get about 1/2 of weight of the cans as clean metal. pics will come after liz comes home (in hospital again). i wish her to view the setup first and my first mamod front wheel repo !. i had to make a pattern wheel which has taken me 3 days (and nights) i used solder to prove the pattern which i melted with a no.20 iron (20 ounce)

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difficult things done straight away...the impossible takes me a little longer

xlchainsaw · Posted: Wed May 14, 2008 1:57 pm Post subject:

old mister malin must have had a real laugh at my expense.

i made two molds using 2 front te wheels. well i had two large blocks of plaster with a te wheel entombed inside. lol i had to smash the molds to retrieve my wheels.lol. i discovered the rims were undercut! only just but enough to bust everything .
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difficult things done straight away...the impossible takes me a little longer

tmuir · Posted: Wed May 14, 2008 1:59 pm Post subject:

I've ready that using that low sodium salt is good for flux.
You melt the slat into ingots and then as it cools it cracks into lumps and you sprinkle this in just before pouring and it will increase your yield considerably.
I will try and find the link
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tmuir · Posted: Wed May 14, 2008 2:18 pm Post subject:

Here are a few good links to topics about flux to improve the amount of metal you can recover from the slag.

http://www.abymc.com/forum/viewtopic.php?t=31
http://backyardmetalcasting.com/f...php?t=778&highlight=salt+flux

Photos of someone melting and casting the salt flux into ingots.
http://backyardmetalcasting.com/f...amp;highlight=salt+flux+aluminium

A photo of some ones bucket furnace pouring aluminium ingots.

http://hep.ph.liv.ac.uk/~gdp/patel/rowan/18-pouring-Al-ingots.jpg

If you want to try sand casting and are struggling to get bentonite it is used by directional drilling machines as mud when boring under roads services conduits or cables and the companies usually buy it by large bags so if you see a crew working and speak nicely to them they may give you a few kilos.
I work in the telecommunications industry and have got myself a small supply from my contractors.
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xlchainsaw · Posted: Wed May 14, 2008 2:36 pm Post subject:

that would be great if i could get some sand. the guys at the shed know of some green sand deposits very close to here. i just opened my plaster mold and it looks good

it looks like my pattern wheel was ok. i hand ground it into a plaster block (half of the wheel) and added plenty of bevel to the edges ect. then i melted solder into it giving me half a wheel. i made two halfs and turned them to fit and soldered together. then i bogged up the imperfections and sanded smooth.i followed the molding vids and now to add the pouring holes ect.

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tmuir · Posted: Wed May 14, 2008 4:10 pm Post subject:

If you were in Perth I would give you some but its a bit heavy to post.

Good luck in finding some locally.
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http://www.freewebs.com/ozsteam/index.htm
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A nice example of an Australian made Scorpion Donkey Engine