On Jan 16, 5:08*pm, " wrote:
To All:

It appears that personalities and other factors overwhelmed the
subject that I thought it best to start anew.

One of those other factors is my physical condition -- more
specifically, the amount of pain I have to deal with and the
limitations placed on me by the physicians, such as limiting the
amount I can lift to about 25 lbs. *Cheating isn't wise since I'm
liable to crush another vertebrae. *Increasing my pain medication is
also unwise, since it causes to pass out... only to have the pain wake
me up due to some crazy angle of my neck or back... which causes me to
reach for the pain pills AGAIN... round & round we go...

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The objective is to produce TWO unique castings -- one forward, one
aft -- for the two barrels on each side of the VW engine.

Volkswagen presently uses ONE casting, flipping it end-for-end when
used on the opposite bank of cylinders. *By splitting the single head
into two individual castings, we can move the exhaust stack to a new
position that is lower than the outlet on the present head, thus
allowing MORE FIN AREA to be cast onto the ends of the individual
heads.

Since these heads are not for vehicles, there is no limitation on the
height of the fins. *If the heads WERE for bugs or buses they would
have to fit UNDER the stock tin-ware, reducing the maximum fin height
to about one inch.

Based on the parting-line flash of new, stock heads, they are cast
using two molds. *To cast INDIVIDUAL heads it will take at least THREE
molds of FOUR different types. *Anyone having actual experience with
finned aluminum castings is encouraged to offer their opinion.

I have drawings & photos of VW heads that I'll be happy to post to
some address where they might be available to all -- and would
appreciate comments as to where such a place might be. *But no
Bluesky, please. *I'm trying to solve a problem; I've no interest in
creating another Chat Room.

-Bob Hoover

Bob,
I have done some experimental metal casting work, but nothing to the
extent you’re proposing; however, such a concept is within reason.
Quite rightly the mold design and preparation are the most significant
aspect of this project, once made though and good foundry can produce
the castings. The end user can than do their own clean up milling work
or if desired such work may be done by the seller. Beyond this I’ll
honor your request for no blue sky flights of fancy, but I hope you
consider posting your drawings on your blog.
Regards
Joe S.