The first of many videos showing how I make aluminium castings in my home made foundry.

In part one I made the sand mould. Now I melt metal and complete the casting.

How to make a greensand mould using a loose piece.

Casting parts for a model engine in aluminium .A sand core is used to make the casting hollow.

Making sand cores as used in Metal casting at Home part 1 and 4

A short video showing how the sand is prepared for use.

Making a greensand mould when there is no flat surface to make the parting line.

Showing how wooden patterns are made to make greensand moulds.

Details of the equpment I use in my home foundry. More details including plans can be found at myfordboy.blogspot.com

How to make a casting from making the sand mould to the finished item. The video has been edited to fit the 10 minute time limit of You tube. It takes much longer than this!

Making sand cores for a greensand mould using Sodium Silicate and CO2 to harden the sand.

Things don't always go well in the home foundry.

Making a small casting in aluminium. A core is used to make the intenal detail of the casting. This is the gearbox for my Stickney engine model. There are some slight differences in technique from my other videos, I am learning all the time!

Casting a pair of flywheels for my model Stickney engine. They will be lead filled and fitted with steel rims.

Full details of making a wooden pattern for a greensand mould.

Casting the pattern made in part 15. The recessed rectangle at the top will be cut out later and is filled in to aid moulding.

Casting ten model cars using a snap flask to make the moulds.

This casting needed a core to produce the required shape. The core could only be supported at one end so a cantilevered one was used.

This was an experiment to see if carbon dioxide produced with vinegar and bicarbonated soda could be used to harden a sodium silicate sand core.

Making a greensand mould and casting an aluminium cylinder for a model hit and miss engine. ( Blooper included ! )

Making a cylinder head for a single cylinder hit and miss engine. Core making moulding casting and machining operations. The engine is an Olds Gearless, a 4 srtoke with no gears. An eccentric on the crankshaft opreates a ratchet wheel to give the necessary timing.

Here I show the complete pattern making and casting of a 12 1/16" flywheel.

I am showing a method of casting I read about somewhere, using a cuttlefish bone as the mould. it worked well on a small item. The size of the casting is limited to size of the bone.

This pattern had some deep cavities and on the first attempt at moulding the sand stuck inside the pattern. Woodscrews were used on the second attempt to key the sand together.

In this video I am advising on which aluminium scrap is the best choice for casting. By using metal that has been cast before you can be assured it is suitable. I would not use drinks cans for example as they contain so little metal and after melting you

get a lot of questions about the sand I use. Here is my first attempt at making my own greensand. The results are very good. It was a lot of work mixing by hand so the next project could well be an electric muller. More details can be found at myfordboy.

Here is a method I tried to make a core box. The wooden pattern for the casting was made with the internal shape formed also. Plaster of Paris was used to make a male mould and then this was used to make the female core box. Sodium Silicate and CO2 were

An experiment to see if my elecrtric furnace was suitable for melting brass. This was the first time I have tried a brass casting. The small size of the furnace limits the amount of metal that can be melted but the results were good. Watch in HD.

In this video I am using a new batch of Greensand from Artisan Foundry. The sand has enough green strength to use as a core. Proprietrory flux and degassing tablet were used instead of my usual salt and washing soda. More details at myfordboy.blogspot.co

I am trying sodium silicate from a foundry supplier, artisanfoundry.co.uk instead of the stuff I originally used from a pottery supplier. The results are much better, this product is thicker and has a brown colour. The core is ready immediatly. 20ml of s

The natural greensand seen here is from artisanfoundry.co.uk

The quality of softwood here in the UK leaves something to be desired. I spotted this timber decking at the DIY store and it has proved to make great moulding flasks. There are grooves on one side only which when placed on the inside of the flask help ho

How a tank is made using a sodium silicate core.

Here are details of my combined crucible lifter and pourer.

A number of viewers have asked for more details of pattern making. This video shows the complete making of a pattern for an Essex turntable. I have included abridged mould making and pouring clips so the end result can be seen. If you need more details o