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I hope I am more successful this morning at 7 am than I was at 10 pm. Last night I had this post almost complete and then I went to Utube without opening a new window and puff it was gone.
My last posting was of the foundry tools and the pattern, Today I will be showing you the complete process with some video's. and a few pictures. So lets get started.



15 minutes later I have the mold ready to take out the pattern



The pattern is removed with the aid of a wood screw



The metal is about ready and the mold is in position ready to be poured



It is always fun to coll the metal and watch the steam fly



A rough casting in no time at all



The machining the casting is just even more fun, in the video I show how to make a keyway without a broach.



Then drilling a series of holes for stops



I got a little carried away with the holes.
72 holes 5 degrees apart around the outside rim
40 holes 9 degrees apart on one face side
45 holes 8 degrees apart on the other side
That would give me a choice to make about anything, only trouble is I dont know what the anything is.

The finished indexing wheel.



Well here goes, the links to the videos, If I was half way smart I would have put the links at the top, then when I goof up there wouldn't be so much to redo.

Making the mold
pouring the metal
Machining the casting

Thats done now, what else can I do wrong now, I had better post this before it disappears to never never land. Hope you enjoyed the videos, if you haven't done sand casting, its fun to learn new things.
Thanks for looking, comments appreciated.

Gallery

Comments

· Registered
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8,785 Posts
Looks like this was a fun project.

I'd love to try metal casting some day.
 

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Soon, I'm going to try some epoxy casting - nothing like that
 

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Interesting and well made. Thanks for sharing. However I'm missing balancing.
 

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Excellent and very informative Brian. Missed my opportunity to take that back in High School. Maybe you will get to router some grooves into your turnings, I'm looking forward to trying that.
 

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332 Posts
Bet you get a lot of real satisfaction from making this one Brian, top marks for job well done
cheers
pete
 

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4,567 Posts
Very nice index wheel, Brian. That was smart to make the 40 and 45 hole patterns as well. I think you have all situation covered for indexing!!

cheers, Jim
 

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2,671 Posts
WOW!!!
Nice job bushmaster.
I remember in high school making and pouring molds like that, both brass and aluminum.
Man you've got a nice setup, so keep up the great work and thanks so much for the look see.
 

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111 Posts
That's awesome, my lathe has indexing included with it but I like yours way more. I made a plywood wheel that I thread on that's numbered to let me know where I'm at. Nice job.
 

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I think you pretty much covered all situations you can come across. It's a great idea and will be looking forward to seeing some projects from it. I don't use mine often but it's a good feeling knowing that you have it. Maybe I'll add the other patterns too like you did.
 

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Is that the "Hole" story Brian? Sorry, the devil made me say that.
Great Job Buddy.

Bob.
 

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That was a very interesting to watch on Youtube. But what was even more fascinating for me, was to watch your videos about the power plant and about sawmilling. Great videos!
 

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Quite a process, nice job.
 

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I hadn't noticed the vidio's so went back and checked them out,wow really nice work and set up.
 

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Brian, You never cease to amaze me with your know-how and ingenuity…thank you for the videos!!
 

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I am always in awe of your videos from cave crawling to machine building to sawmill maker you just do it all man GREAT JOB :<))
AND YOU ALSO DESERVE THIS :


NICE :<))
 

Attachments

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DaveGlx That's one beautiful indexer!!!
I really like the idea of a lift handle! Hmmmm!!!
 
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