Casting Aluminum Wheels | Old Timey Casters

recently I decided to try my hand and making my own old timey [Music] Wheels I started by making a 3D model in Rhino the wheel will be about 6 in in diameter and it'll be super wide at 3 in I originally intended these wheels to be for a cart for The Foundry [Music] furnace [Music] I intended to have a 21 wheel pattern if I wanted super wide wheels I could use the pieces as a split pattern if if I just wanted wheels that were about an inch and a half I could simply use half the pattern once I had the 3D model I just needed to generate tool paths and cut it out on my [Music] [Applause] [Music] CNC the wood I'm using is 1 and 1/2 in thick popler and is a nice dense wood for routing something like this to be able to sand both sides in relation to each other I needed to temporarily glue them together here I am using super 77 once all the sanding was done I could resplit the [Applause] pattern I used a few coats of polyurethane to seal the surface to find the center of any Circle you can draw an arbitrary line across the circle divide the line in half and draw a perpendicular line towards the center do this as many times as necessary until you feel confident that you found the center [Music] here I using sodium silicate sand for the mold I am hoping for a nice texture on the inside of the wheel to add to that old timey [Music] flavor after a few sodium silicate casts I have found that actual mold release works better than talc for keeping the patter pattern from sticking to the mold the texture of sodium silicate sand is a bit like mashed [Music] potatoes I am adding screws here to help support the Deep mold cavities here I am flash curing the mold with some CO2 this penetrates about an inch and gives at least a little bit of strength to the mold here I'll be using talc on The Parting line and I probably should have left a little bit more as it ended up sticking a bit the best thing about sodium silicate sand is how forgiving it is small small areas can be patched before the sand cures here I'll cut the gates and runners [Applause] and now I'll melt some [Applause] aluminum [Music] [Music] here I'm degassing and removing the drops [Music] [Music] let's see how it turned out here you can see the old timey texture that I was hoping for I'll just need to cut off the gates and trim The Parting [Music] lines [Music] [Applause] I am using a bit of masking tape to keep the overspray to a minimum I'll end up sanding the lip to get a crisp line aluminum primer will etch the surface and help the paint bond to the aluminum [Music] here are the finished Wheels I don't know what I'll do with yet but I think they turned out [Music] great oh and by the way a friend told me you can't call it a deep dish wheel unless you can fit a dollar on the [Music] lip

Channel: Brian Oltrogge

Views: 550,732

Keywords: Casting, aluminum, aluminium, molten, metal, pattern, making, project, cast, DIY, backyard, foundry, metal working, CNC, wood working, Brian Oltrogge, Grunblau, Design, Studio

Id: __pXiYlLrkw

Length: 11min 55sec (715 seconds)

Published: Thu Jun 22 2017