casting a lead keel

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sue_bagnall

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We need to cast a new keel for the boat we are restoring. We have the drawings for the new keel shape and wood like to use the old lead. Does anyone know of a company that can cast a keel. I am bassed in Essex so someone near would be good Many thanks
 
You could of course cast it yourself! Just need a big boiler affair, gas type burner and large cast iron pot, make the cast out of wood soaked in water or even make it in the ground with clay. But dunno anybody who could do it for you down there.
 
I well remember as a child casting molten lead into the hollow in a damp brick. The resulting explosion of steam splattered molten lead all over the kitchen curtains and my brother and I were lucky to escape severe burns.
The thought of staggering about trying to pour a ton of lead out of an old cauldron into a wet mould doesn't bear thinking about.

Has anyone actually done this in the quantities needed for a keel? All the lead has to be molten at the same time - if you try adding more layers to lead that has already solidified then it won't bond properly and delaminates.
 
Irons Brothers in Cornwall www.ironbrothers.com is the onbe that springs to mind. Not local to Essex, but a very specialised trade!

Have you considered casting your own? If it is a straightforward shape then it is not too difficult to make a pattern. If you already have the lead, that is half the battle and more than half the cost!
 
Did think about doing it ourselves for about a minute it too frightens the life out of me. We do have the lead 2 tons of it. Many thanks for your thoughts
 
This is one of those jobs which , on the face of it, looks like a doddle. In actual fact it is anything but. The usual receptacle for melting the lead is an old cast-iron bath, with a 2" water pipe outlet from the plug 'ole. Naturally, a steel plug has to be made and fitted to the end of a long rod, supported by a frame over the bath. The footings for the bath need to be very soundly constructed, not just a pile of secondhand bricks. A ton of molten lead on the loose makes for some very permanent injuries [eg, no feet!] The mould must be below ground level for the same reason. It is usual to provide cores where keelbolt holes are going to be required, and these must be securely mounted in a framework over the mould. It really is a job which should be given to a company who cast non-ferrous metals on a regular basis; a foundry. Just the experience of casting smaller amounts of lead would put me off going for a whole keel. There are just too many things to go wrong.
Peter.
 
It sounds scary, but in the "good old days" boatyards cast their own keels alongside the boat shed as 2 tons of lead is not easy to transport. To keep it simple, most keels were relatively shallow and long with rounded ends. Gets more difficult if the keel is deep or has a lot of shape.

There is a good section in one of Michael Verney's books on how to do it.
 
If you look on the Wooden Boat Forum, they are many posts on this. Use a steel bath in case the cast iron one is cracked. A blower is needed for the wood or coal fire and the comment about putting the form below ground is sound. There is a good(and funny) article about two brothers casting the keel for an Oughtred Grey Seal in a an issue of WB about 3 yrs ago. Two tons is a lot, but not beyond the capability of amateurs. As you have the lead ( look after it at todays prices!) It might be an idea to talk to Irons Brothers. Esp. if you can make the mould. I have done a bit of this and there is quite a lot that can go wrong, and quickly.
Andrew
 
There are still a few small founderies about - look them up in yellow pages.

In my limited experience with founderies (I got some aluminium panels cast a few years ago), they are surprisingly aproachable and willing to help. Not as expensive as you might think, either.

I can't remember the name of the foundery I used, but I think they were in either Waltham Cross or Hoddedon somewhere, so not too far from Essex.

Much safer than trying to do it yourself.

Edit: I've just found it - The Enfield Foundary, Waltham Cross. Phone number was 01992 710224, but it was some time ago!
 
Only one-and-a-half bits of advice to add: Make sure your foundry will buy your drillings and shavings back from you. If your keel has to be drilled for bolt-holes, etc, the price of the swarf will at least buy you some frosties for afterwards!
And when you've done cooling the casting, and it's time to shape your beast, go to your nearest hire-shop and hire the biggest planer they have. DO NOT BE TEMPTED TO BUY ONE!
 
molten lead and wet wood doesn't bear thinking about. I remember making some lead weights out of lengths of copper tubing which I had stood in some slightly damps sand. Fizzy molten lead is not an experience I'd fancy repeating!

there was a thread on woodenboat.com a while back with a video of some chap re-casting his keel

think this is the video:

http://youtube.com/watch?v=0zHeQijtWjw

make a mould out of plaster, lay it on really thick, then bury the mould in the ground or in sand to support it, pour the lead, attack the plaster mould with a mash hammer - it breaks up really easy after the extremes of heat its suffered (makes sure the plaster has had a good while to set of completely first though, if there's any residual moisture in the plaster it liable to crack when the hot lead gets in
 
Do it yourself, we did.
Build a steel box the size / shape of the keel with one side open.
Suspend it over a large fire and melt the lead in the box.
once it is full scrape off the slag and rubbish and leave to cool.

Did this and it worked well, and yes the boat is still sailing 20 years later.
 
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