Sand Processing Machine Build

I've started collecting the bits to build a sand processing machine like that used by OlFoundryman on YouTube.

So far I have a 1 HP motor and a 3/4" shaft with bushings and locking collars.




The motor has a 5/8" shaft.  I'm thinking of using a lovejoy coupler instead of the rag join used on OlFoundryman's machine.

Found Foundry Furnace Outer Shell ?

Nabbed a dryer drum.  It just might make a nice shell for a larger electric aluminum furnace.  Maybe use sodium-silicate sand mix to form the hot face and wire looms.  Back that with rock wool if the stuff I have is still good.   If not upgrade everything to take brass.

UPDATE:   This is a bit on the big side but still might work.   Would be better suited for a spin casting sheild.

Wood Fired Aluminum scrap melter.

Various people on AlloyAvenue put together setups to melt aluminum scrap like car rims.

For the most part I am copying that design.

Here I have welded the stand and am laying out the grate.

The welding is not great but with enough heat I can stick mild steal together and have it stay.

Currently I am welding the grate where the rebar crosses.













Shortly after I fired it up.

I was getting roasted trying to remove the floating embers.  The corrugated sheet metal was drafted for use as a heat shield.

There is another section of this sheet in the water under the barrel to catch the aluminum.  Protect the plastic.

Kubota BX mower anti-scallop wheel.

Cast a wheel for the BX's mower.  It weights in at about 4 times what my previous largest cast was.

This was a test to see what could and would go wrong.  A lot did but then I was trying a few new things.  I am pleased that the results are as good as they are.

Started with a wood pattern.  It is butt ugly but could be used if cleaned up.    Thinking most of the holes seen in the first image is due to shrinkage.   Not surprising given how massive this thing is.   Would like to do a version with spokes.

To create the axle hole the head was cut off a 5/8th inch bolt.  The cut end was rounded and polished.  The bolt was coated with soot from a candle.   The threaded end was embedded in the sand above the pattern.  When the pattern was removed the bolt remained.  After casting the bolt was pressed out of the wheel.

I have an image of the bolt that will be added later.

The top of my casting seem to come out smoother than then bottoms don't know why.  Maybe the folk on alloyAvenue know.

They say it there is porosity it will show in the gates.  Looks good.

Converting 'dirt' to greensand

The sand left over after removing the clay from my dirt is at least as fine as the sand I am currently using, which may be blowsand.

My thinking is that since this sand is already in a clay matrix it may behave more like natural green sand after the debris and excess clay is removed.

I removed most all the clay from the first batch and added some back.  It seems to make a better green sand than that made with the same clay and blow sand.

Started aa 2nd batch iwhere I left just a bit more clay with the sand.   About 3/4 of it went through my window screen sieve after drying.  The rest went into the bucket to rotate in the concrete mixer.  But when I tried to temper it there was not enough clay.

OK it has occurred to me that I can test the green sand for clay to sand by weighing a small sample, washing out all the clay, drying it and weighing again.   They key is to weight dried sample prior to and after removing all the clay.  So the following procedure should work.

1. Take a dry sample of dirt and screen out the rocks and twigs.
2. Wash out all the clay.
3. Dry and weigh the sand.

That will give me a base line of clay to sand in the soil.  Then I can determine how many times I need to was the dirt to remove just the right amount of clay.

1. Combine dirt with water.  
2. Drain off clay once.
3. Test ratio of remaining clay:sand.
4. Drain off a 2nd clay.
5. Test ratio of remaining clay:sand.
6. Repeat till only sand is left.

At this point I should know how many times to rinse to leave a clay:sand mix suitable for green sand.  This presupposed that I let the experiment rest for a fixed time between mixing and draining.   Maybe use the drill to mix each time to ensure uniform mixing.   Maybe that can be eliminated later.

Made a few tools.

Cranked up the wood lathe and made two rammers and two risers from a pear tree branch.

Also made a flask and a riddle with 1/4 inch screen.  Only useful in removing gravel from sand.  Need to make ones with finer mesh. Going to try window screen to get facing sand.







Swapped the Ben Franklin TrimOsaw for a metal cutting band saw and some cash.  It was a neat saw the bandsaw was a better fit for my immediate needs.

I have succeed in making a few pounds of clay.   This would be much easier if one staggered the tubs so that the first could be drained into the next by opening a tap or cap.  Maybe do 3 tubs instead of two.  May give that a try just for kicks and giggles.

Welcome to No Man's Land Foundry

Back in my uni days I spent some time in the art department learning to make jewelry, cast bronze and forge blades.   Since my retirement I have been longing to return to foundry work.  This time I may make machine parts in addition to art object.  In the past my foundry work was done using lost wax investment casting.  This time I would like to try sand casting and lost foam.

I have collected some equipment from other hobbyists, flea markets, and craigslist.

Yesterday I dusted off the Kerr 666 burnout oven.   Today I made a crucible for melting aluminum from an old propane bottle and a device to remove the hot crucible from the oven.  It is made from a steel shelf brace cut in half and riveted.   At some point I plan to switch to graphite crucibles.





The firebrick in the oven looks a bit odd.   I did a test run with the crucible and the oven came up to red hot and the thermostat cycled.




The temperature meter does not work.

Green sand is a mixture of sand and clay.  Others have documented this so I will restrict myself to the work I have done in that direction.


My ground has a fairly high clay content.  So I opted to try refining some of it.   I had some on hand from digging a pit for an irrigation manifold.  So I dumped it into a feed tub and added water.











I have 3 choices of sand including what is locally called blow sand.   None of it can be used without screening.   The hope is this can be automated to some degree. 



This machine  was used by the local news paper to vibrate lead scrap to settle it.  At least that is what I was told.  My plan is to adapt it to screen sand.







What's next?

• Melt some aluminum to make ingots
• Work on refining clay (or buy kitty litter)
• Work on screening sand.