On Mon, 12 Jan 2009 22:38:54 -0600, "Maxwell" #$$9#@%%%.^^^ wrote:



There is also the possibility of molding this in plaster, but that's another
story.


unless you've tried it you would have no idea how dangerous that
suggestion actually is.

firstly the strength of plaster vanishes to nothing beyond a certain
temperature. that temperature is just 5 degrees celcius above the
melting point of aloominum.

I have tried the technique to cast a mills 0.75cc diesel crankcase.
this is a tiny thing about an inch and half by an inch and a half in
overall dimensions. relatively tiny and easy to work with.
it was done lost wax.
a day after the plaster was set the mold went into the oven to melt
out the wax. it was then cooked up to about 180 degrees farenheit for
a while (2 hours afaik) to evaporate off the moisture. it stayed in
the oven overnight (I've never been allowed to use the oven again) it
was then given 15 minutes in the microwave to really dry it out.
it was wrapped in a cloth and raced out to the workshop hot.

it looked alabaster white and as dry as a piece of chalk.

when the aluminium was poured into the mold a guyser of molten
aluminium ejected to the ceiling of the workshop. this seemed to
continue for some time. an examination of the mould later showed it to
be totally empty. I dont know how dry you need to get it but I gave it
a fair go at getting a bone dry mould.

I have to ask you what your experience is in casting.
have you ever done any of this yourself or is it something you've
watched?

Stealth Pilot