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This week’s “Tally Ho”..,

Wansworth

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Joined
8 May 2003
Messages
15,025
Location
SPAIN,Galicia
There are a hundred and one things that are going to be needed for the boat,lots of lodging knees that were wrought iron,mast fittings,,goose neck ete etc which could be bronze cast as well.
 

AntarcticPilot

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Joined
4 May 2007
Messages
6,685
Location
Cambridge, UK
The Port Townsend Foundry has been around for years and is well known. Right back in the very early videos (pre-Patreon) Leo was talking to them about bronze types and bronze components.

I am sure that there is a reason why things are being done in the way that they are. I don’t recall the lost wax method being used for large components but I may be wrong.

This isn’t any old boat. She’s the biggest surviving Albert Strange boat. If Fifes are the vintage Bentleys of the old boat world, Albert Strange designs are the Bugattis. Oh, and she won the first bad weather Fastnet.

I am one of the three thousand and odd and happy to be one.
Lost wax is used for casting statues far larger than these floors. And bronze floors are (as he notes in the video) a vast upgrade on the original wrought iron floors.
 

doug748

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Joined
1 Oct 2002
Messages
9,570
Location
Plymouth
.............

I am sure that there is a reason why things are being done in the way that they are. I don’t recall the lost wax method being used for large components but I may be wrong.
..............

I think you are correct. Lost wax is doable for small components but the larger they get the more high tech it becomes, the cost of aerospace items is astronomic (heh ) and only offset by batch production. In this case the making of wax patterns might be as tedious as the timber ones and certainly more expensive.

In the days before Health and Safety, I have seen lost plastic used to good effect. Polystyrene patterns can be fabricated and cut using hot wire, the results embedded in petro-bonded sand and the melt used to directly evaporate the pattern.
Very quick cheap and effective, not too great for the lungs or the planet. You might do it in a fifth of the time but leather underpants should be worn as the gas pressures would be unpredictable at that scale.

I don't contribute regularly but sent him a wedge when he was in the UK, told him to spend it on beer. I'll buy his team another good drink when the hull is wetted.

.
 

AntarcticPilot

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Joined
4 May 2007
Messages
6,685
Location
Cambridge, UK
I think you are correct. Lost wax is doable for small components but the larger they get the more high tech it becomes, the cost of aerospace items is astronomic (heh ) and only offset by batch production. In this case the making of wax patterns might be as tedious as the timber ones and certainly more expensive.

In the days before Health and Safety, I have seen lost plastic used to good effect. Polystyrene patterns can be fabricated and cut using hot wire, the results embedded in petro-bonded sand and the melt used to directly evaporate the pattern.
Very quick cheap and effective, not too great for the lungs or the planet. You might do it in a fifth of the time but leather underpants should be worn as the gas pressures would be unpredictable at that scale.

I don't contribute regularly but sent him a wedge when he was in the UK, told him to spend it on beer. I'll buy his team another good drink when the hull is wetted.

.
I did as suggested and sent an email asking why they chose not to use the lost wax technique. I'll be interested to see the response!
 

DownWest

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Joined
25 Dec 2007
Messages
8,424
Location
S.W. France
.

In the days before Health and Safety, I have seen lost plastic used to good effect. Polystyrene patterns can be fabricated and cut using hot wire, the results embedded in petro-bonded sand and the melt used to directly evaporate the pattern.
Very quick cheap and effective, not too great for the lungs or the planet. You might do it in a fifth of the time but leather underpants should be worn as the gas pressures would be unpredictable at that scale.
ed..
Friend did a stint learning with a sculptor. He used styrofoam patterns and they worked very well in sizes similar to floors. Casting was in ally, but would be good for bronze.
Lost wax is good for precision stuff, but plain old sand casting is good enough for floors. Seem to recall that our friend's the Romans thought that one up. Another usefull idea they did for us :D
 
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DJE

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Joined
21 Jun 2004
Messages
6,875
Location
Fareham
I enjoyed that one! But I was wondering where the money for this is coming from - he spoke of material costs of $11,000, just for the bronze floors, and I guess the foundry costs would double that quite easily, without taking the cost of making the patterns into account!
I seem to remember that the Live Oak for the frames was $80,000!
 

Keith 66

Active member
Joined
21 Jun 2007
Messages
1,186
Location
Benfleet Essex
I was a bit surprised at the video of the casting, Sure they wore fireproof jackets, but Jeans? & no face or eye protection! Get a splash of molten metal in your eyes & its white stick time. I have done metal casting & a face visor is or should be mandatory.
 

burgundyben

Well-known member
Joined
28 Nov 2002
Messages
5,973
Location
Colwell Bay
Lost wax is hugely more expensive method of casting than sand casting.

You have to make the wax, then shell it, melt out the wax, then cast. If you get a problem, you need another wax to start again.

Sand casting with patterns such as he has done is lowest risk and cost.
 
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