BackyardMetalcasting.com - Lionel's Laboratory

[sandcrab]

Just a couple of photos to start. I didn't have a digital camera then so some were shot in B&W.

These are the patterns and core boxes to cast the block. It is wet sleeved so the water jacket was tied together in one core.
The crankcase cores carried the waterjacket cores and the timing gear and flywheel end cores drop into core prints.
The oil filter core is locked in by the flywheel end core.





The first good block. It was hard so I had it annealed at a heat treat facility. It is actualy block number five. Cold
shuts, inclusions and various other calamities condemned the first four.





The complete layout of everything it took to build before I painted it and put it together.


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If you think you can't do it, you're right!

[HAVEHEATWILLCAST1]

I see it looks like you got all the parts there is.
Even the valves ?

How does it run ? Any idea of the power?

We do have one thing in common: I try to cap a "one" too
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Heat them up, mold them out.

[sandcrab]

Good eye I got the bugger!

It runs great. The valves don't show up very well in the photo but I think they are standing on there heads next to the cam and lifters.The power is about the number one question I get at shows. Stock answer is after hearing it, if you'll give me 1/2 HP/cu.in., since it displaces a little over 11 cu.in. that would put it at around 5 HP.
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If you think you can't do it, you're right!

[HAVEHEATWILLCAST1]

What is your 1/3 scale taken from ?
I know thet don't make 66cu in small blocks but I know you lose a lot on dia s.
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Heat them up, mold them out.

[sandcrab]

The 1/3 scale is taken from any measurement divided by 3. For instance a bare block is 21" from the water pump boss to the bell housing
surface. On mine it is 7". I carved a wood master pattern so it is 21/3 x 103% to give a double shrink masterpattern. I poured an aluminum
working
pattern that is 2% smaller and then when I pour the cast iron I get the final 1% shrink. On the firedeck in theend cores and on the pan rail
I added abour .080" for machining. With the finall casting I use Motor Manual numbers divided by 3, enter them result in the DRO of the mill and drill and tap pan or head bolt holes.

With 1/3 scale, volume is 1/27th. 1/3x1/3x1/3 for X, Y , and Z axis. The reason it is 11+ inches is a long story, otherwise it would displace
350/27 or 12.96"
_________________
If you think you can't do it, you're right!

[HAVEHEATWILLCAST1]

I did not even think of the Z axis.
I've been out of a machine shop much too long.
_________________
Heat them up, mold them out.

[welder19]

That is awsome!!!

I'd love to see some more pics, maybe with some more detail if posible.

Is it all alum?

welder19

[HAVEHEATWILLCAST1]

[petersenj20]

Thats enough to make a grown man cry!
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Beeeeerrrrr. MMMMmmmmmm, Goooooooooddddddd!

[sandcrab]

These are the RTV silicon molds used to cast the distributor cap and rotor in Alumilite. I used the mold frame to give the outside form. The patterns
are wood with brazing rod inserts for the plug wire connection on the cap. After the mold had cured, additional pieces of the same length were
embedded in the mold and when the plastic was poured they were bonded in position.



A sprue and whistler were added to the cap mold to vent and give an indication when it was full. Alumilite has a 1 1/2 minute pot life so it must
be poured quickly.
_________________
If you think you can't do it, you're right!

[welder19]

How much time do you have wraped up in building it?
Or did you not even keep track

welder19

[sandcrab]

I started carving the block pattern in the first photo in April of 1997. It first ran in April of 2004. I was working full time until 2003 so I only had
evenings and weekends until then. I've always estimated about 4000 hrs. I kept a detailed journal for the first four years, but got lazy about it
and did not keep records through the completion.
_________________
If you think you can't do it, you're right!

[Garry]

I am impressed

Does the unit have a water supply? waterjacket in the head or block?
Are those 14 or 23 deg heads?

http://www.youtube.com/watch?v=N8TXMUaC9Os&feature=related
Need a supercharger for it? LOL
Regards
Garry
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confucius say: Find a job you enjoy doing and you will never have to work a day in your life

[HAVEHEATWILLCAST1]

Here is another pic of his engine I posted in the V-twin thread.
http://www.littlemachineshop.com/gallery/photos.php?Qwd=./2005-09%20GEARS&Qif=GEARS%202005%20%284%29.jpg&Qiv=thumbs&Qis=M

sandcrab , are you a part of the Little Machine Shop or just in a club or something?

[sandcrab]

Garry, the block has wet sleeves, but the heads were cored for runners and water jacket. It took me a year to get patterns and core boxes worked
out and then probably 5 or 6 pours before I got a pair that could be used. It takes 16 hours to build up a pair of cores, and then another
8 hours to clean up and anneal. I don't make extras , although I have sold seconds as paperweights for $75.00. After machine work and
consumables that's about $2.00 an hour for my time.





HHWC, I am not associated with the My Little Machine Shop group, but they are often a vendor at shows I attend. They took these photos at
a Portland, Oregon show a couple years ago. I am a member of the Early Day Gas Engine and Tractor Association (EDGE&TA) which is
dedicated to preserving the old engines, but the group likes anything Internal Combustion.

Some of the group have designed blowers for the Challenger V8 which is a cast aluminum kit roughly patterned after the flathead Lycoming V8
which was used in the Cord in the '40's. It had the intake and exhaust in the valley to simplify the porting. One of the group borrowed my
miniature heads and designed a pattern that would allow the ports and chambers to be machined. This converted the model to OHV and then
they added blowers and cogged belt drives. They can get almost 5 PSI boost .

There are examples on You Tube at The Good Guys Nationals in Pleasanton, Ca. I'll look for it, but try "miniature V8's".

http://www.youtube.com/watch?v=R1Ygf83DwlA&feature=related

There are a lot of videos, but the one of the block and cast cranks is a kit
being developed for sale. I don't know the status.

The link for the kits is Cole's:

http://www.colespowermodels.com/engines.htm

I could not find the blower there seems to be some changes and the company moved from Ca.

This same builder machined a Hemi from the solid in 1/4 scale and I helped him by casting the water pump. I used the plastic model kit pump
for a pattern, put some extra material for the aluminum shrinkage and poured it solid. He machined the impeller cavity and passages. I have
seen videos of it running nice Hemi sound.

Here is the pump with the follower for a complex draft. It is easier than coping most of the time.



Material was added to the outllet to allow for machining and to give that surface some draft.