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Post by Deleted on Mar 7, 2014 17:11:14 GMT -5
doing my side project finally getting some time to cut foam. i was going to do a dana 25 lost foam casting in aluminum but after talking to the teacher he said the aluminum would break if i hit a rock so now i am making a foam mold and casting a cover out of ductile iron. i can't do the lost part because it will add carbon to the mold and i would have to take that into account and i don't wanna worry about all that. so ill get some pics up later, i have made some of it and today i cut a piece to short so hopefully i can get in the lab tonight and make and glue the whole thing together. once done i will write a cnc program to mill the WO logo into the cover.
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Post by Deleted on Mar 7, 2014 17:49:39 GMT -5
Schimmmmmmmms, you and your Instructor may be overthinking the aluminum cover. IMHO Ductile Iron is over the top strength for the application, and I am surprised by your Instructors concern  . Aluminum diff covers have been an aftermarket favorite for years, keep in mind the stamped steel cover has not cracked or bent in 60 years, unless your doing the Moab rock crawl thing I do not believe you will ever have a problem with the aluminum. Your at an Engineering school, correct!?? MHO, Lee |
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Post by Deleted on Mar 7, 2014 19:57:44 GMT -5
X 2 WITH MR. LEE ON THIS ONE THERE SCHMINSTEER !! SOMBODY AT YOUR SCHOOL IS GIVING YOU WRONG INFO...LISTEN TO YOUR ELDERS WHEN IT COMES TO JEEPS ...LIKE LEE HE HAS BEEN AROUND BEFORE DIRT WAS INVENTED AND HE DAMN SURE ISNT GOING TO STEER YOU WRONG... 
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Post by Deleted on Mar 7, 2014 20:09:02 GMT -5
lee we cast ductile iron a lot, so its easier for me to do that also the aluminum is cast but the alloy we cast only has a 5-10% elongation so if i were to hit a stump as i drive or something big which i will be driving this off road on my land then i will run into a problem. we cast 535 and i think 356 alum and although both are good alloys they are relatively low strength and 535 does a ton of really weird shrinking. I'm going with the iron i just don't want to risk the aluminum breaking, i have broken this stuff before and the cover is not very thick. to get the strength of the stamped steel cover i would need 3-4x the thickness of it for aluminum. the iron is just about the same thickness.
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Post by Haines Garage on Mar 7, 2014 21:07:23 GMT -5
Sometime...student can become teacher.
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Post by Deleted on Mar 7, 2014 21:18:51 GMT -5
Why not cast a Willys overland logo? You can put it wherever you want. Or is it Willis Overland ?  |
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Post by Deleted on Mar 7, 2014 21:45:44 GMT -5
i was actually going to cast the logo in originally. that was my main reason for doing this but i have since decided to cmc it into the front of the cover.
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Post by Haines Garage on Mar 7, 2014 23:22:24 GMT -5
I have a feeling you will, and the rest of Us can't wait to see..
Point is DO IT! Grab the Bull by the horns. I have great faith in you Sir Schimms...
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Post by Deleted on Mar 8, 2014 0:13:53 GMT -5
the only thing holding me back now is time, we are casting gray iron on monday. and then there is break but hopefully when i get back from brake i can finish making all my stuff, i hope to go up north during break and install my custom made (by me) door locks in my truck. i also made a new shifter adapter for my pto so it goes through the original hole in the cab. it was a quick mill/ lathe job which was great. those photos will go into my build thread/ the pto thread here.
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Post by Haines Garage on Mar 9, 2014 19:06:35 GMT -5
When you finally get to the casting. I want one. Someday, you Sir Schimmster are going to be somebody..I just know it!
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Post by Deleted on Mar 9, 2014 19:41:59 GMT -5
well i was close to done but i decided to change up my design a bit to make it better for the ring gear fit. so i will be redoing most of it after break. hopefully i will cast it this semester if not I've got 4 more years here.
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Post by Deleted on Mar 19, 2014 23:44:56 GMT -5
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Post by Haines Garage on Mar 21, 2014 20:41:40 GMT -5
Very Cool Sir Schimmster....Could you explain whats going on there? I am really interested.
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Post by Deleted on Mar 23, 2014 16:03:03 GMT -5
ok the photos are out of order but heres the deal originally i was going to lost foam cast it which means i would make the foam mold as shown above ( not done yet) then i would create a big riser on the bottom out of foam and a sprue of foam. i would put it in media and pour the aluminum down the sprue and that would fill up the casting, however i cannot do that because of the ductile iron. i would have to compensate for the carbon of the foam with a calculation to make sure the ductile iron stayed in the correct carbon range. that would require a precise mix in the crucible to get the exact amount which i don't want to deal with so what i will do is make the mold out of foam then ram green sand around it open up the mold pull out the foam ( break it out if needed) then cut my gating and close the mold. from there we pour the iron in the mold and pray it comes out. this is the construction of the foam mold with the original above it to check for size. when this is all done i will have to machine it some for fitting the ring gear. I will also machine the WO logo on the front of the cover and i need to put in an oil fill plug and a breather.
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Post by Deleted on Mar 23, 2014 16:03:39 GMT -5
the breather will go on the top of the casting so when i do launch boats and go axles deep the diff won't fill up with water.
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Post by Haines Garage on Mar 23, 2014 16:57:10 GMT -5
Great explanation! Thank you.
I want to tell you that I am most impressed with your efforts. I can't wait to see the finished product. Keep us posted. I have great faith in you Sir Schimmster.
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Post by Deleted on May 2, 2014 10:39:04 GMT -5
its poured, at 6 am thursday morning we were finally ready after all night wednesday working on stuff. we poured 2 things and mine was the 2nd and lower of the two to pour. i have photos and a video of the other thing. ill throw up some stuff later. i think you guys will enjoy the other thing as well.
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Post by Deleted on May 2, 2014 19:45:09 GMT -5
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Post by Deleted on May 2, 2014 19:47:51 GMT -5
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Post by Deleted on May 2, 2014 19:48:42 GMT -5
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Post by Deleted on May 2, 2014 19:52:20 GMT -5
so ill run you all through it. i made a pattern out of foam, then i sanded that pattern to have draft so it would pull out of the sand. i sanded the outside and inside, the inside i cut with a heat wire as shown then sanded smooth. i put a direct pour riser sleeve on it with a ceramic filter. i then rammed it in chemical bonded sand (no bake) and let the sand harden. once hard i flipped it and did the other side then removed the pattern. i opened the flask and let it all dry then put on the blue mold glue. once that was done i put the mold together and placed it in the foundry area to be poured. the last few are after my shake out and then shot blasted it. if you see the very last picture my friend made a transmission case for his project car. i have a video of his being poured then at the very end they poured mine but that part wasnt filmed. ill post it up in a bit so you can see.
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Post by Haines Garage on May 2, 2014 20:22:05 GMT -5
Sir Schimmster! I think that is FANTASTIC! Thank you for sharing all of that here. I have been waiting to see it...whats next??  |
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Post by Deleted on May 2, 2014 20:34:40 GMT -5
next i will cut off the riser and write a program to have a WO cnced in the face of it. i have to drill and tap in a plug and drill and tap in a nice breather. i will also have to machine it to height properly. that will be a bit interesting.
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Post by Haines Garage on May 2, 2014 20:36:35 GMT -5
next i will cut off the riser and write a program to have a WO cnced in the face of it. i have to drill and tap in a plug and drill and tap in a nice breather. i will also have to machine it to height properly. that will be a bit interesting. Can't wait to see it. I find this kind of thing very interesting! |
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Post by Deleted on May 2, 2014 20:36:56 GMT -5
Very interesting Schimmmmmmms, whats up with all the platform scale weights ?, are you melting them down for your projects ?, thanks for posting! Lee |
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. Aluminum diff covers have been an aftermarket favorite for years, keep in mind the stamped steel cover has not cracked or bent in 60 years, unless your doing the Moab rock crawl thing I do not believe you will ever have a problem with the aluminum. Your at an Engineering school, correct!??
"h
