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Full Aluminum Cast Locust Bench

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Project by ErikF posted 05-20-2017 10:41 PM 744 views 0 times favorited 6 comments Add to Favorites Watch

Thought I would try some lost foam casting to make a bench.

I cut a 1” dado around two loose black locust boards and the filled the dado with Styrofoam. After that I rigged up a base and glued it to the foam in the dado.

The first bench I tried failed due to using loose sand, second attempt worked better since I mixed up a large batch of green sand. Biggest problem is packing the sand around the legs since the foam isn’t very rigid.

Second issue is handling this much melted aluminum. I’ll have to build a new pouring handle prior to the next try.

It was a fun project that was able to be knocked out in an afternoon. Second bench turned out well enough to have as a useful piece of shop furniture…it should also last a long time since it’s a combination of two materials that don’t tend to breakdown.

-- Power to the people.





6 comments so far

View DocSavage45's profile

DocSavage45

8219 posts in 2559 days


#1 posted 05-20-2017 11:51 PM

Eric, creative and innovative. I’m thinking maybe you could cast the alluminum and then secure to the bench eliminating some blow out?

-- Cau Haus Designs, Thomas J. Tieffenbacher

View Don W's profile

Don W

18411 posts in 2284 days


#2 posted 05-21-2017 12:07 AM

those are not locust boards, they are locust planks! You should be good to set the D9 on there when you need to work on it!

-- http://timetestedtools.net - Collecting is an investment in the past, and the future.

View Jerry's profile

Jerry

2261 posts in 1365 days


#3 posted 05-21-2017 02:28 AM

Really interesting.

-- There are good ships and there are wood ships, the ships that sail the sea, but the best ships are friendships and may they always be. http://www.geraldlhunsucker.com/

View Andre's profile

Andre

1309 posts in 1523 days


#4 posted 05-21-2017 02:32 AM

Ahh, to be young and ambitious! If only I new 30 years ago what I know now? Great project.

-- Lifting one end of the plank.

View shipwright's profile

shipwright

7617 posts in 2515 days


#5 posted 05-21-2017 03:14 PM

Looks like fun Erik. For larger castings I used to use a molasses valve. I was pouring lead for keels but it should work as well for aluminium. It also eliminates the need to move any molten material by tipping or ladling. I was able to do a constant pour of 6,000 lbs.
More details in this blog. http://lumberjocks.com/shipwright/blog/21382

-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fibreglass trees. http://thecanadianschooloffrenchmarquetry.com/

View ErikF's profile

ErikF

550 posts in 1961 days


#6 posted 05-22-2017 11:43 PM



those are not locust boards, they are locust planks! You should be good to set the D9 on there when you need to work on it!

- Don W

No kidding, right? I want everything locust these days

-- Power to the people.

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