I actually took the first steps towards actually having a small FOUNDRY on my property, lol… I have no idea what the neighbors will think, and dont really care.
and by “foundry”? I mean… I melted the aluminum, I adjusted the MELT… then cast it into the approximate shape I wanted… THIS resulting piece of metal? was what i started machining on, in my attempt to make a flashlight from scratch.
I know when i started fabricating with hand tools, from watching OLD LUMENS pictures of builds? I felt sort of “macho”. When i finally had my own “half a milling” setup going? Felt more “macho”. When i bought a small lathe and started to use it for more operations? I felt even more “manly” and “macho”.
but THIS? good lord, I am simply walking around sweating testosterone… LMAO.
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its only baby steps in the right direction? But… if i can refine the operation and build a bigger apparatus I need? I might be able to cast a WHOLE LIGHT, ten machine out the insides, such that the entire light is one solid piece of aluminum… that would be no pill to sink losses, no sink to light body losses… nothng. It should be, i am hoping if i can make it work… other than opening the battery compartment to swap batteries? the entire whole body from inside to outside is the one gigantic “pill” and “heatsink” in one piece.
the “macho” aspect of this? It is highly labor intensive… I spent about 12 hours straight, working over a raging coal fire fed air to make it hotter… giant burns and blisters erupt INSTANTLY even through the heat-proof welding gloves… i get sunburn in the middle of winter from red-hot molten liquid aluminum… i have any number of bad cuts on my fingers from sheet metal is sharper than it looks.
i am reminded of the members name “VestureOfBlood”… IE, his name means he has “invested actual BLOOD” into his own modding and working on lights?
well, whatever “spell” was completed? I bled like a stuck pig into a vat of molten aluminum, and didnt dare drop it, because 10 hours in?? i dont want to lose all that work trying to accomplish this.
PS - this is in no way “commercially viable”, by the way… the amount of heat, the length of time, burning straight thru solid steel melt-pots in minutes… re melting mistakes over and over… all before any machining starts?? it is in no way a commercially viable thing… i am trying this just to see what its like to do it… lol
(and i am sweating testosterone all week after doing it, lol, very “macho” work)