Fun with castings

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Finally got these finished up. Painted them, sanded the tops, then clear coated and attached to the truck.

Forgot to mention that they're made from an old water pump and FJ60 pistons, so technically they are both aftermarket and OEM!
Great Job on the emblems! Any chance of making a batch and selling them.....or trading for a set of used 60 pistons? :)
 
Damn, you beat me to it! Well I guess it's nice to see the results before I tried it! Looks like it's worth a shot!
 
Those are awesome! I think they look cooler than the originals do. The graininess of them fits the more rugged theme of the land cruiser better. Great work, and thanks for sharing. If you ever wanted to take the time to explain the process, I think it would be a great read.

thanks,
John
 
View attachment 1020741 I wish I could, but my truck is in storage due to renovations going on. I don't have one in my rebuild file either. Maybe someone else can chip in? There is a separate plastic part on the inside that is equally unobtainium.

@Racer65 , maybe these parts could be added to your lineup. I would but a pair if they were available.
 
side vent rear inner part not sure if you would want to make them out of aluminum





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Finally got these finished up. Painted them, sanded the tops, then clear coated and attached to the truck.

Forgot to mention that they're made from an old water pump and FJ60 pistons, so technically they are both aftermarket and OEM!

They turned out great looking... and very cool that they are recycled cruiser parts.

Did you follow an online step-by-step of any kind? I'd be curious to learn how to do this and give it a try.
 
Did you follow an online step-by-step of any kind? I'd be curious to learn how to do this and give it a try.

No, I used to run a small foundry in a tooling shop, where we made aluminum castings every day. We had nicer equipment, but the beauty of foundry work is that it really hasn't changed much in the 5000 years or so that it's been around, so with a little care you can have great results for almost no investment. I'm sure the are lots of resources out there to learn it, and I'd encourage anyone who is interested to give it a shot. When I was working in the industry, I helped set up an art foundry at the university near by, and that was great fun. Teaching people who considered themselves artists about a dirty, industrial process that they then found could allow them to make beautiful things. Pretty eye opening for some of them to see that industry and utility can also be attractive and unique.
 
If people are interested, I'll see about putting a short video together of my little foundry making the emblems. Also happy to share whatever I know if someone wants to try to give this a shot themselves.

My equipment list is short, scrounged or made most. Can be done on the cheap, and was really fun to share w my 11yr old. We made some aluminum army men too!
 
Very cool video... and very cool job running a small foundry. The DIY'er in me really wants to try this. I've made my own vacuforming table... why not a forge and casting.

So do you have a sacrificial piece inside the sand that the aluminum consumes? That's the part that I'm not understanding clearly...
 
Honger, the old, plastic badge is what I used as a pattern. The way it works is you put your pattern down on a board, place a box called a flask around the pattern, and then pack sand over your pattern inside of the flask. This creates the bottom of the mold, known as the drag. You then flip the drag over and do it again with another flask on top, which creates the cope (top of the mold), and the cope includes a hole to pour aluminum into the sand. The part you're curious about is where you separate the cope from the drag (remember that they're two, separate boxes), and you strip the pattern out of the sand, leaving an impression of the pattern in the sand. The cope is then reassembled on the drag, so there is a void in between the cope/drag where the molten aluminum goes. I need to post some more pics--once you see it, it'll make total sense.

PabloCruise, nothing more complex yet. A good friend of mine is 7' tall, and we're making the pattern to cast fork components for a bicycle that will actually fit him. That'll require a little more care than what I exercised while whipping out a couple emblems!

Mijfwb23, I get the 'another hobby' thing. At least this one is cheap! Let me know if there is anything I can do to help you on your way to having a home foundry. There just aren't enough people casting metal in the world.
 
Honger, the old, plastic badge is what I used as a pattern. The way it works is you put your pattern down on a board, place a box called a flask around the pattern, and then pack sand over your pattern inside of the flask. This creates the bottom of the mold, known as the drag. You then flip the drag over and do it again with another flask on top, which creates the cope (top of the mold), and the cope includes a hole to pour aluminum into the sand. The part you're curious about is where you separate the cope from the drag (remember that they're two, separate boxes), and you strip the pattern out of the sand, leaving an impression of the pattern in the sand. The cope is then reassembled on the drag, so there is a void in between the cope/drag where the molten aluminum goes. I need to post some more pics--once you see it, it'll make total sense.

Okay, so that makes sense to me. How do you pack the sand? Is it wet? When you separate the cope from the drag and strip the pattern out, what keeps the sand from collapsing in on the void?

Sorry for so many questions... I'm just really intrigued by this!
 
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