Power Sand Fluffer, LFMC...
And a Self-Igniting Burner
As the Proof-of-concept Sand Fluffer was a success, I opted to improve the idea by lining the support framing of the electric mixer with the same 1/8" mesh...
The larger capacity can riddle about 120lbs of material in 30 to 45 min... nothing compared to a commercial unit, but still twice as fast as doing it by hand.
There is a slim chance that I'm too hung-up on the perfect consistency of the molding sand, but it seems to make a difference in the quality of the molds.
Note: Section 12 was posted on the same day as this section (#13), here is a link back to it if this is the first you're seeing of the "Sand-fluffer" project...
These are more patterns that simply can not be extracted from the sand. The sharp cut-in's are the problem, as well as the detail of the lettering.
I will always try to extract a pattern a couple of times, as I know that it's a skill that is certainly worth developing, but LFMC within a bonded sand will have to be part of my repertoire of tricks as well.
These 2 (two) Castings were lost due to cold pouring and the excessive paint that was originally there to slick the pattern for easier extraction.
15 hours later, a new set of patterns are machined and will be cast later next week.
This castings will be part of the monster plaque for the coveted "Toys for Boys" Radio contest by Chez 106 FM, Ottawa's Classic Rock Station.
$130,000 of prizes all to one winner... and C'est Tre cool stuff, 2005 Mustang, boat, motor trailer, and on & on...
www.chez106.com for details...
This is about 150lbs of BBQ housings and analog Cable TV distribution boxes...
I enjoy the fact that I'm able to give a new lease on life to material that collectively we have all paid a high price for it's extraction from the earth.
This material is far cleaner than Lawnmower motors and will offer a more consistent alloy for casting.
This is a stash of Yamaha snowmobile cylinders that I've been saving for a special occasion.
This alloy is reserved for the "Toys for Boys" plaques, as it's only fitting that such a prize be made from an alloy that once was just such a toy...
The plaque on the left was one that the pattern did extract from the mold, while the one on the right is near perfection and is a raw unpainted LFMC casting via Cope & Drag. The only consideration is major venting out the back of the casting...
This wouldn't be installment #13 without a little bit of greif..
I won't drag you through the sequence of events that got to this picture, beyond about a pound of molten metal flowed backward into the burner and destroyed the unit, starting with shredding every vane of the blower fan...
I'm cool, no sweat, I have a spare burner, within an hour to 1.5 hrs I'll be back at 'er...
This is the replacement unit, it's looking a little rougher than I remember, but a spare is a spare...
The pump assembly was seized solid so I cannabalized the original of the now scrap burner.
As an aside, I wonder if such a pump could be used for very small hydraulic applications... I have a pair of 1" cylinders with about 8" of travel... No real project to apply them to yet but having a pump would be a start.
The big black block that is hinged open is a 10KV ignition transformer that can source 25ma of current (5ma is the threshold of lethal current if passed through the chest).
Note: Read Disclaimer !
All control/safety circuitry is gutted and discarded, against my better judgment. I hate this stuff, and any attendant risk that comes with it.
But as I honestly believe that I have to face these challenges, I'm driven into the unknown with soiled pants yet again.
The shiny toggle switch is for the ignition coil, while the black switch is the mains power to the whole unit.
This is a quantum leap improvement, and has cut 10 minutes of each re-ignition of the furnace.
The coil is energized for the first 20 to 30 seconds and the burner develops a self sustaining flame after that.
All wiring is grounded like crazy as the furnace is an all steel device that I do not want to be electrically hot, The next step will be to GFI the burner outlet...
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