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Any recommendations/help with aluminum casting?

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  • OneEighthBit
    With wings alone

    Any recommendations/help with aluminum casting?

    All,

    The Horsa glider cockpit at the Jet Age Museum is slowly pressing on after a quite 18 months and one of the upcoming tasks is to finish off the rudder bar mounts and linkages so we can get everything buttoned up below the floor.

    These were originally cast alloy (the sort I don't know but as it's a Horsa, it would have been "cheap") and then just faced and drilled. I've made a CAD model up from reverse engineered Airspeed drawings and had a friend 3D print it in ABS plastic for test fitting and just so we can get a tactile sense for what we're dealing with.

    Next step is to get it cast so I thought I'd throw it out to the forum, especially the cockpit builders, who might have some experience at getting this done in the UK.

    Basically I'm looking to send a 3D "master" (minus the holes) somewhere that can pack it in sand, pull it out and cast two copies it in some reasonable cheap aluminium.

    I'm aware aluminium shrinks so I'd need advice on how much to scale up the master before 3D printing it. Part itself takes up about 5.25" x 2" x 3.5" and has a volume of 18.6 cu/in.

    Any leads, recommendations of folks you've used in the past? Needs to be in the UK for VAT reasons.

    "The best way to stop a crack in the fuselage spreading is to drill each end with a one eighth bit."
    @HorsaJed | Jet Age Museum Horsa Cockpit Project
  • boguing
    Rank 5 Registered User

    #2
    I haven't used them yet, but have had a brief chat with them about a job I need done. Their advice was 1% shrinkage for my alu alloy bellhousing.

    http://www.fbullettandco.co.uk/services/

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    • 12jaguar
      Rank 5 Registered User

      #3
      we've used various people over the years and generally once you explain what it's to be used for they add the pattern into one of their other jobs and you'll get it relatively cheap. Recently we've used East Coast Castings of Watton Norfolk, which came in FOC. Shrinkage rates can be found by a quick google found this for guidance https://www.haworthcastings.co.uk/ne...n-sand-casting

      John
      http://www.stirlingproject.co.uk

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      • FarlamAirframes
        Scrap Metal Man

        #4
        I have used white metal casting - purchased the metal, melting pot, ladle and silicone (for casting) from Tiranti.
        Kind Regards,

        Brian

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        • Whitley_Project
          If in doubt apply heat..

          #5
          I would recommend James Virgo - he produced all my Whitley castings and wouldnt send them anywhere else. Tell him I sent you. You can post him the patterns and he will send the castings back to you.

          https://www.jamesvirgodesign.co.uk/
          Last edited by Whitley_Project; 8th December 2018, 16:52.

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          • OneEighthBit
            With wings alone

            #6
            Thanks all! I'll look into all of these. The fact we can 3D print the master and scale as needed helps a lot these days!

            "The best way to stop a crack in the fuselage spreading is to drill each end with a one eighth bit."
            @HorsaJed | Jet Age Museum Horsa Cockpit Project

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            • QldSpitty
              Rank 5 Registered User

              #7
              Yes the technology is growing.
              Attached Files
              "If the C.O. ask's you to be Tail End Charlie...just shoot him!!!....A Piece of Cake.
              http://spitfirea58-27.blogspot.com.au/

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