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Derek

Making my own EFI intake... The First Casting

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Well I finally got some time to get over the foundry to pour the first manifold.

If you are new and need to come up to speed here's a link to the design stage

http://forums.hybridz.org/showthread.php?t=121021

 

And a link to the pattern making

http://forums.hybridz.org/showthread.php?t=121478

 

 

Here is the core assembly all glued together with the stainless tubes and the bronze bushings in place

 

 

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This is the pattern with the flask around it.

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Ramming the sand

 

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This is the drag or bottom of the mold with the pattern removed

 

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Setting the core. Cores makes castings hollow.

 

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We decided to do a dual pour. Don't try this at home! I'm running the camera by the way.

 

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The moment of truth.

 

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I'm really happy with this

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I ran out of time but tomorrow I'll shake out the cores and post a few more pics of the casting.

 

 

Derek

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holly &$&$&$ that is awesome derek i need to make it out to ocala to see that thing. or you could just take a detour and go back to ocala though daytona!!!! lol looks awesome... hrmm i might have to get one of these when your done....well i guess i will have to cut it and weld on a plenum though. cause you know i cant live with out boost!!!!

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Thanks guys. I'm really happy with the way it turned out.

 

 

holly &$&$&$ that is awesome derek i need to make it out to ocala to see that thing. or you could just take a detour and go back to ocala though daytona!!!! lol looks awesome... hrmm i might have to get one of these when your done....well i guess i will have to cut it and weld on a plenum though. cause you know i cant live with out boost!!!!

 

 

That's why they make band saws and tig welders!

 

 

Looks like trumpets?,thats a manifold?-pretty cool anyways :-)

 

Well I figured if it doesn't work as a manifold I'd park a seal behind it, teach him a tune and go to work at a circus!

 

 

I'll knock the cores out later this morning and post a few pics

 

Derek

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We decided to do a dual pour. Don't try this at home! I'm running the camera by the way.

 

DSC_0044_Large_.JPG

 

 

Pouring molten aluminum with a short sleeve shirt and no gloves... that is what I'm looking at there, right?

:shock: :shock: :shock:

 

Manifold looks great, btw!

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I wondered what took so long for someone to pick up on that!

Seriously both of these guys (one is the owner) have been doing this continuously since both were in high school and they're both in their early fifties. The first time I saw it I couldn't believe it because I'm like mister safety at my shop. Now when they pour bronze and iron it's a whole different story. They look like spacemen.

 

I don't want this to turn into a debate about foundry safety so if people want to go that direction then let's start a new thread.

 

Thanks

Derek

 

 

Pouring molten aluminum with a short sleeve shirt and no gloves... that is what I'm looking at there, right?

:shock: :shock: :shock:

 

Manifold looks great, btw!

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Derek, do you know what type of furnace they are using? A lift out crucible furnace? Tilting furnace or cupola furnace? I'd love to see some pictures of their setup. Also what type of sand are you guys using? I've been reading a lot of Steven Chastains book's with a lot of enjoyment and had always wanted to do what you're doing. http://stephenchastain.com/store.htm

 

Thanks,

Tyson

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Now for the small world award. Steve is a frequent visitor to the foundry. He's known the owner for quite a few years and I've met him a few times. He's really a great guy and has a firm handle on the home brew "build it on a dime" mentality.

The foundry uses induction melters. They use Olivine green sand. I've got a bunch more pics that I'm going to be uploading to a gallery in the next few days. I'll let you know when I've got it done.

 

I'm sure we can work Kevin Bacon in here if we try hard enough!

 

Derek

 

Derek, do you know what type of furnace they are using? A lift out crucible furnace? Tilting furnace or cupola furnace? I'd love to see some pictures of their setup. Also what type of sand are you guys using? I've been reading a lot of Steven Chastains book's with a lot of enjoyment and had always wanted to do what you're doing. http://stephenchastain.com/store.htm

 

Thanks,

Tyson

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Now for the small world award. Steve is a frequent visitor to the foundry. He's known the owner for quite a few years and I've met him a few times. He's really a great guy and has a firm handle on the home brew "build it on a dime" mentality.

The foundry uses induction melters. They use Olivine green sand. I've got a bunch more pics that I'm going to be uploading to a gallery in the next few days. I'll let you know when I've got it done.

 

I'm sure we can work Kevin Bacon in here if we try hard enough!

 

Derek

 

Thats awesome!!! I just ordered another one of his books, and decided to buy footloose too...(jk, no footloose) Can't wait to see the pictures and the finished product!! Jealousy and scheming is setting in :D .

 

Tyson

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Derek, do you know what type of furnace they are using? A lift out crucible furnace? Tilting furnace or cupola furnace? I'd love to see some pictures of their setup. Also what type of sand are you guys using? I've been reading a lot of Steven Chastains book's with a lot of enjoyment and had always wanted to do what you're doing. http://stephenchastain.com/store.htm

 

Thanks,

Tyson

 

Its "Green Sand" in an old school hand rammed pattern box, it mainly consist of bentonite and Oklahoma#1 sand. Pretty easy to make just don't get your moister content wrong or it goes pop! I would ask them to smut(acetylene) the mold before closing it up next time, it will give you a satin smooth surface.

 

Nice to see that the first run came out well,Good job!

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