Using the melon baller and the sheet metal
cutter, a small 'cup' is cut where the spure meets the drag and gates
cut from the cup to the pattern.
Water is 'swabbed' where the sand meets the pattern. The helps to firm the sand prior to pulling the patterns out.
The patterns are lightly tapped with a metal
rod to help separate the patterns from the sand. A tiny gap will likely be
visible around the edge of the pattern.
Careful! One pattern has been pulled....one to go.
Both patterns have been removed and the molds look pretty good.
Now it is time to insert the sand cores. I cut
the cores to 3" lengths. The core print is 2" long and the core needs to
extend into the casting 1 inch. Now you see that the core print just creates a hole to hold the rest of the core in
Both cores are firmly in place.
Now I lightly sprinkle white flour onto the surface of the mold halves. The flour helps the liquid brass flow in the mold.
Usually, I use compressed air blown through the flour filled bag to "spray" the flour on the the mold surfaces.
Everything in place and lightly dusted with flour...time to put the cope back on the drag.
The mold is back together...one more step.
Use a small U-shaped wire to scrape the surface.
We will be place weights on top of the mold and the helps to
distribute the weight evenly across the surface.
Weights are place on the mold and it's ready to
receive the melted brass. The weight of the metal being poured into
the mold would force the 2 halves apart and allow metal to run on the ground if we didn't have the weights on top.
<Next Page> Melting the metal
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