On Jan 13, 4:54*am, " wrote:

...

But I never even considered casting a VW head. *I DID try to increase
its fin area by welding but that's a different story. *What I'm
looking at now is the possibility of casting INDIVIDUAL cylinder
heads, which offers some unique challenges. *However, with regard to
rapping the pattern prior to lifting, I'm considering casting the fins
SEPARATELY from the 'body' of the cylinder head (ie, the inlet &
outlet stacks, the heavy bosses for the head stays and valve guides.
The fins would *then be attached to the 'body' by TIG welding. *

If you are going to make the fins separately you might consider
machining them from stock, rather than casting them.

Then how about sticking them onto a wax block that is the form
for the cylinder (or the head) so that when you cast the cylinder
or the head the pre-made fins weld to the cast metal.

How about if you make the fins from pure aluminum (for
good heat transfer) but make the body from an alloy for
better strength and heat resistance. Maybe you can
cast the cylinder or the head in aluminum bronze.

Maybe I'm crazy.

Just some thoughts.