casting aluminum stock myself...

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sedstar
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casting aluminum stock myself...

this is HIGHLY frustrating. You first have to MAKE enough heat to melt the aluminum. THEN you have to have “more” because things start cooling down q-u-i-c-k once out of the furnace. At THAT elevated temperature (above liquidus)? Things are happening like… your melt which is a precious commodity? Is “burning off” into aluminum oxide quite steadily.

raise the temps of the furnace more to give yourself more time? you start burning it off like lighting paper on fire, lol… aluminum cans, which is of course the most popular “thing” to melt to GET molten aluminum at home? Has got to be one of the crappiest sources of aluminum going.

you see, when you melt metal (as any self respecting bullet caster can tell you?) you have to have a big load of the source metal… you melt it, and you pick out the “crap”, and theres plenty of it. Its called “dross” and its the waste equivalent of “slag” from making steel… its a total waste product.

The dross is lighter and riding on top of your melt… and its POROUS so, its sucking up your precious commodity of melt like a sponge. You have to “flux” the molten liquid, which makes it all smooth and creamy temporarily, allowing you to mix it thoroughly… and the waste comes up top where it can be pulled off to the side withOUT sucking up metal like a sponge… and you have a very limited time window of opportunity to accomplish this.

THAT leaves the final melt of very much cleaner metal? which you can now make clean INGOTS from.

but, you still havent made diddly *&^% yet… when you have enough ingots of the right size? you can NOW get a melt going, with the clean metal… which of course is oxidizing off at the same temperatures, but, its a ton easier to flux THAT clean melt, drag off the tiny bit of dross, then you can get a nice clean “pour” into your mold.

===========

its basically the same procedure as making bullets at home (i am a bullet caster, i got my technique down pat) to do this with aluminum. The problem is scaling everything UP. Higher temperatures… much higher… greatly shortened working times… higher and quicker oxidation (basically your precious melt evaporating steadily).

melting pots are GONE, your working with a big furnace, and putting a little “crucible” in it, and working out of THAT. For some idea of what i am going thru? i have a a coal furnace (a big one) simply ROCKING, the size/shape/thickness of the crucible? are all fairly critical.

its all a dance, and its frustrating.

a smaller diameter crucible? heats up fast, but, it doesnt HOLD enough melt for what i want to pour.
also, to “flux”, i have to get down IN THERE into red hot molten aluminum with tools and flux. it should be obvious that the small diameter crucible that works well, is way too small to “work in”.

thinner crucible? heats up awesome, but, it burns thru in a time frame measured in “minutes”.

thicker crucible? actually nice, and, it wont burn thru quick… but, its now getting too WIDE to be any good. A whole coal furnace’s heat, on a 3 inch diameter thick walled ductile ironpipe and base? thick enough it lasts… but, only the bottom inch or two is glowing cherry red like it needs to be. the DROSS from aluminum cans? theres so MUCH of it, that it forms a thick cap on top of the small melt, and theres more dross than melt… and i havent even made the ingot yet…

cant even get a “pour off” into a fluxing container? because what little melt is under the thick layer of dross? solidifies up the sides of the pipe trying to pour. and the dross is sucking up even more of the precious melt like a sponge.

I just today, paid 31 dollars for a couple inches of thick ductile iron pipe, with a thick cap on it… i got it working okay? but… the DROSS from the cans? is so bad and so much of it, that it gummed the whole thing up, its now useless.

you cant MELT dross, its no longer aluminum… its mostly aluminum oxide, which wont melt.

===============

internet information? isnt all that helpful. You have these “arseholes” online, who really just want to nmake a video people will watch, simply to get their 2 dollars beer money off of the views… they dont care if it works or not, they just need views. THEY are trying to act as if you can melt aluminum with a propane torch and just play with it. Which you CAN, but… only for purposes of making a medallion or a pendant. you cant get a big melt going.

my only “success” has been when i accidentally made ingots, by a small thin crucible burning thru, and retrieving the shiny puddles and sawing them into shape for re-melting… which of course burns thru another crucible.

===========

a 55 gallon trash bag of clean empty beer cans? sure, it weighs a couple pounds… but, you LOSE so much of it to dross, i couldnt cast a solid 2-d maglite, lol…

===========

the only way i am going to get anywhere? is by buying ingots ready to go… which put me up against the MARKETPLACE. All the “arts and crafts” f*cktwits out there in internet land? THEY want to make hippie jewelry, and “americana art” (which is latin for “junk”)… they wanna cast their girlfriends NAME on a desk plaque… etc etc…

and THESE idiots have ruined the price of clean ingots online? because the little wifey that wants to play “artist” wants to cast NECKLACE PENDANTS… and thinks paying 6 dollars a POUND for aluminum ingots that aint worth 2 bucks a pound to make her life easier? its just marvy to her…

===========

so… what am i GONNA do? glad you asked…. quitting is not an option. My couple of small “wanna be ingots” i saved up and got one small GOOD melt fluxed and poured? worked good enough i am machining ONE small flashlight out of right now.

I have to buy online ingots cleaned and ready to melt/flux/pour for home casting?? but, i have to BUY a minimum of 100 pounds of it at once, in order to get “up above” any weight that the single mommy hippie artist could possibly want.

then, i STILL have to waste pounds at a time, figuring out exactly WHICH diameter/thickness/height of ductile iron crucible? will “work” without clogging shut useless (thown away, bye bye 30 dollars) one after the OTHER until i get just the “momma bear” crucible that “fits” my particular setup.

when you SEE it all being done in a video, and they have a “build” plans ready? Thats all tuned, by trial and error, to THEIR furnace’s heat, to their furnaces shape and size… to their timing and everything.

but… as all compared to the sheer COST of buying and shipping “3 inch stock” to my house?? so i csn literally “play” with it to get good enough to scratch machine a light? thats expensive to buy 3” stock per foot… as any machinist here can easily tell you…

i am taking it in the rear end without lube, getting myself to the point i can make stock at home to work with.

shrugs

this rabbit hole is a tad deeper than it looked on the surface, LMAO.

i also have any number of cuts and burns and blisters to show for only ONE small light i am actually cutting on right now, ha ha.

With enough black coffee and cigarettes? all things are possible…

I am currently still shipping… REAL GENUINE CREE xp-g emitters, the classic… brace yourself? as low as 20 cents apiece!! Check out the SALES THREAD, everyone is happy… then PM me

SALES THREAD:
http://budgetlightforum.com/node/52528

if you are into reloading? this is my site… I inherited the remains of what was once arguably the best reloading site on the internet… its the “BLF” of reloading sites…

http://reloadbench.freeforums.net/

if you think night vision would be cool? It IS… this site i am a member of, and its basically the “BLF” of home made scratch-built digital night vision. They are at the leading forefront of advanced DIY for digital night vision, and thats gun mounted or handheld… builds rival and exceed commercial offerings…

http://nightvisionforumuk.com/

The Miller
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wow educational, would like to do melt down all the old alu we save for that reason
I saw old fire extinguishers make fairly good crucibles and they can be found in different sizes.

allcool
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Maybe go to a auto junkyard and buy some old damaged aluminum engine heads, timing chain covers, valve covers, etc,,,. Cut them up and melt em down.
Probably get them for real cheap if they are banged up and broken/cracked. Might even get some high quality alum alloy or 6160 ..?

Just a thought…

vwpieces
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I cast my own lead bullets and find things of this nature fascinating.

Most scrap yards will sell to you. May be 2X what they will pay you but no where near $6/lb.

I have scrap computer hard drive housings, stripped clean and since scrap prices plummeted I have no desire to cash them in. Most PC heatsinks are aluminum too. Local recycling centers?? Even local garages… intake manifolds, cylinder heads, transmission housings… can be broken up to remove the steel.

Before I started casting I had scrounged together 250 lbs of lead from range scrap, wheel weights, linotype pig ingots, roofing material rolls and Old plumbing. Most of it was free. Acquired more over the years than I can use up per year.

old4570
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Used to do die casting ….

yep ! In small amounts its a pain … Aluminum Melting temps and everything make it a whole new ball game to casting bullets … Though we used electric furnaces that held Gallons of molten aluminum … Some perhaps 40 gallons or more The smaller ones might have been 10 to 20 gallons ( long time ago ) No problems with cooling , unless your talking about how long it took to cool .. The furnaces ( melting pots ) needed to be serviced from time to time , and it took an entire day to empty and cool …

And then there is the casting procedure / process that needs to be right or you end up with garbage …

I would seek out a casting company / business that does small jobs ( often sand casting ) .. and see if they would not part with some supplies …
I even recall there were some community type work shops here and there that did casting on a small scale .. ( Like bronze ) ( U know , artists )
Hell when I was turning I just called Hawker pacific / commonwealth aircraft / and asked them for some hard to get materials …
They asked me what I wanted them for and I told them I needed materials for model airplane engines .. They said sure , no problem !
Nothing politically incorrect or sensitive about model airplane engines …

Sourcing stuff can be a pain .. I don’t know what Bar costs these days ?
But sometimes you just got to ask whats in the off-cuts bin .. Some companies will allow you to raid the rubbish bin , others want $$ just for talking to you ..
Machining stuff can be fun and frustrating …

 Always remember , the easiest thing in the world to do , is to expel hot air from your lungs and through some vocal chords ..
The resulting sound may , or may not be worth listening too ….

 

Lightbringer
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allcool wrote:
Maybe go to a auto junkyard and buy some old damaged aluminum engine heads, timing chain covers, valve covers, etc,,,. Cut them up and melt em down. Probably get them for real cheap if they are banged up and broken/cracked. Might even get some high quality alum alloy or 6160 ..?

Yeah, wasn’t too long ago I had to have a cracked head replaced. Got the old one back… well, offered to me, but what’m I gonna do with it except use it as a big-ass paperweight?

Had I known, I wouldda saved it for the OP to pick up. Big Smile

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Rufusbduck
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Sliding glass and window doors and frames, door sills, bicycle parts(wheels, handle bars, seat posts,etc.), beach chairs, lots of stuff. This should be an interesting and challenging topic in its own right with some forums of its own.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

Turningbluechips
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I’m sure if you found a machine shop in your area they could be persuaded to sell you aluminum chips/turnings at or close to what they would get paid at the scrapyard. I’m sure you would also get a much cleaner melt with this material opposed to old beer cans.

Firelight2
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Fascinating reading sedstar. Never thought about what it would take to die-cast aluminum. Thumbs Up

Be sure to show us a picture of your little flashlight after you complete the cast!

ImA4Wheelr
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Very informative OP sedstar.  Had no idea how tricky casting aluminum is.  You probably have already explored this, but just in case.  Monitor Craigslist for oxygen and scuba tanks.  The tall thin medical O2 tanks are very common and always listed weigh around 8 lbs.  I think the next size up is the typical scuba tank size.  Those weigh a hefty 22+lbs.  I would think they would be a high quality alloy. I've picked up a couple each for future projects. 

Best wishes on your endeavor.  Really sounds difficult, but potentially quite rewarding.

sedstar
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aw, i got temporarily discouraged when my 30 dollar crucible drossed shut and i couldnt chisel it out, lol…

after dinner, i just about buried it in “coking coal” and re-stoked back up and cooked it off soft, heh heh

managed to get another small “ingot” out of it, and got all the softened dross out in a clump. “achievement unlocked”.

=============

i’m getting there… the name of this game? is just to concentrate on MAKING LITTLE INGOTS. They look bad? but…. scratch one and its bright shiny metal underneath… when i have a little stock of them? thats good clean metal to melt down and flux and cast it.

when i finally GET to melting ingots? i can do an easy FLUX and pour.

theres almost no difference between my ingots i am making? and if i were to get “high quality” aluminum, say,like engine heads to melt down. The reason being?

you could GIVE ME 6061-T6 “rod stock”, and after its melted down and re-cast into a different rod size? its no longer “6061-T6” any longer…

the 6061 refers to the “melt mix”, and the T6 is the heat treating designation… melting it down and recasting in anoher stock rod?? gets referred to as “356” generically in the industry…

i can melt down marine engine heads? pistons? top of the LINE aluminum stock?

after melting and casting? its just “356”… which is ironically what melted beer cans are referred to as after meoting and casting, LMAO…

=============================

buying ingots, or, buying better solid metal to melt easier? will beless WORK, but… wont actually yield me a “better product”

a GOOD flux? yields me a half decent result, and once machined? it looks pretty…

=======================

i’m getting onto the home stretch now, i think… at least for what i need it for… all i need to do right NOW is concentrate on making a few more ingots, than i can make a bigger piece of stock.

theres no practical way to do heat treating and “working” cold or hot at home… the results? will never satisfy any engineers blueprint specs fo stock… yet? it will be overkill for making flashlights and other parts i need.

now that i finally gota crucible that wont burn up with taking a match to it?? i’m in the home stretch, i just gotta keep making a few more ingots before i get greedy and try to cast stock again.

i already bought the right grade of sand and clay to make a decent casting sand, that will come after “ingot fun”…

its working, its just a “war of attrition”. I will WIN, but… it will be a “pyrrhic victory” if you know the term.

==================

PICS when i get a little more done…

With enough black coffee and cigarettes? all things are possible…

I am currently still shipping… REAL GENUINE CREE xp-g emitters, the classic… brace yourself? as low as 20 cents apiece!! Check out the SALES THREAD, everyone is happy… then PM me

SALES THREAD:
http://budgetlightforum.com/node/52528

if you are into reloading? this is my site… I inherited the remains of what was once arguably the best reloading site on the internet… its the “BLF” of reloading sites…

http://reloadbench.freeforums.net/

if you think night vision would be cool? It IS… this site i am a member of, and its basically the “BLF” of home made scratch-built digital night vision. They are at the leading forefront of advanced DIY for digital night vision, and thats gun mounted or handheld… builds rival and exceed commercial offerings…

http://nightvisionforumuk.com/

jack-bkk
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why not buy clean aluminium ??? price is less then 2 usd a kg

CRX
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Interesting stuff.

djozz
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Keep the story going sedstar! You’re doing cool stuff , and your great style of posting about it almost makes up for the lack of pictures Smile

sedstar
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JACK-BKK QUOTE why not buy clean aluminium ??? price is less then 2 usd a kg
ENDQUOTE

really? well, THATS a relief. I’ll just send you the number of my local scrap yard, with you calling them from bangkok and telling them what to buy and sell prices at? i should be all good. (kidding, dont hit the rude button on me…) but seriously though, the scrap yard will pay pennies per pound for “scrap steel”… but, you go down and want a few pieces of scrap steel? to practice welding? OH, no… they want a couple dollars a piece to practice welding, all of a sudden its expensive “plate stock”, LMAO…

where do i go BUY it? i cant get it at walmart. whats the shipping cost? EBAY costs from 3 to 6 dollars a POUND for cleaned aluminum ingots… my neighbors beer cans are free… this is WORKING, i’m telling you…

plus? when i finally BUY good aluminum? i dont wanna RUIN it learning… this is perfect for learning on

===========

up until now… i have been trying to make more heat, or, just to get it into the crucible in a timely fashion?

i had a GREAT melt going. the 3 inch black pipe was glowing bright, i was just BOMBING clean cans down in, as fast as i could throw whole cans in they disappeared and melted. I know a good thing when i have it? i was just whizzing thru a great melt…

when i saw sparks flying around? this cant be right… i pull the crucible?? good LORD, i melted a 3” “endcap” like cheese.

you cant get this stuff at lowes or regular stores… i had to find a plumbing supply place that sells to big contractors to find it… i did not think it would have been possible to melt a 3” endcap? another good pic when i post pics…lol

i’m at the end of a coal pile, and every year a little bit left over stays on the bottom, i rarely get to the very bottom, its a mix and a pot-luck right now… i’ll have to watch out for this in the future if it ever happens again… super bright yellow steel is way too hot, note to self… funny thing is, if i WANTED to melt inch thick steel? i could never accomplish it… this was with the AIR closed off all the way, that must have been “coking coal” from a power plant run my buddy got mixed in with the regular house coal, lol…

it was funny, i just tapped it with a wrench? it was sillyputty soft, lol… pity though, i was making ingots left and right, that was one of the best fires i ever made, lol…

With enough black coffee and cigarettes? all things are possible…

I am currently still shipping… REAL GENUINE CREE xp-g emitters, the classic… brace yourself? as low as 20 cents apiece!! Check out the SALES THREAD, everyone is happy… then PM me

SALES THREAD:
http://budgetlightforum.com/node/52528

if you are into reloading? this is my site… I inherited the remains of what was once arguably the best reloading site on the internet… its the “BLF” of reloading sites…

http://reloadbench.freeforums.net/

if you think night vision would be cool? It IS… this site i am a member of, and its basically the “BLF” of home made scratch-built digital night vision. They are at the leading forefront of advanced DIY for digital night vision, and thats gun mounted or handheld… builds rival and exceed commercial offerings…

http://nightvisionforumuk.com/

MILSPEC
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ImA4Wheelr
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Where to buy aluminum?  Did you see Post 10?  You can get those tanks quite cheap if you are patient.  I got my medical tanks (8 lbs without head) for $7 and my scuba tanks (22+ lbs for $15).  Also look out for baseball bats.  Maybe mag wheels?

Rufusbduck
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There’s a local service for hydro testing scuba tanks. When they fail they can no longer be used for scuba. If there are any dive shops in your area you might drop in and see what they to with them. Offering more than the scrap yard should still be a win win.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

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I considered getting into what you’re doing and building a gas fired fuurnace. Wish I had access now to what we used for casting during junior high school metal shop. Gas fired furnace, clay graphite crucible, casting sand and boxes… Or, wish I had ideas I have now back then.

One factor that may be causing problems is the coatings on the can. The plastic lining on the inside and ink on the outside are adding a lot of crud to your melt.

I remember years ago when I did a lot of fishing we’d often build a fire when night fishing. We’d toss our cans in the fire and watch them melt. When the fire burned out there was always a bunch of aluminum nuggets buried in the ashes. Nice solid little nuggets of aluminum that had melted and pooled in the low spots.

sedstar
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all good ideas… coolness.

yeah… online i like “backyardmetalcasting.com” they guy made me think “hey maybe i can DO THIS” and not need a degree in metallurgy, lol.

funny thing is, i dont even NEED to be good at the “casting part”, it can come out rough… i am just gonna machine it all off anyways. its all good.

backyard website? has a link to a “forum” like this one, just not nearly as many people into it, though… one guy? said HE was a machinist, and was just “casting machining rounds” so he went with cheap home made casting sand, as it didnt matter, cast it rough and machine it off.

i was like “whoa, thats ME! good deal! thats what i wanted to do!”

=======================================

i bought another 3” pipe and giant endcap today, will get back to a few more ingots tomorrow, i guess. Its just “busy work” to make ingots now, more or less… the more i have, the more “machining stock” i have now…

it will be “a while” before i ever get adventurous enough to try to cast a light body or anything, though, if ever… i’m happy casting rough cylinders to machine on… and its even easier to make a “flat” of aluminum to mill it flat…

i mean, i know about a fingernails worth of all this, but, its WORKING. if i get any better, thats just gravy. i’m content now. i promise PICS when i have some more ingots and make a bigger piece of “stock” up that would actually be a little “pricey” for me to go buy it…

actually? the “mix” cans are made out of? isnt a bad alloy at all…. its okay for machining. i checked… MAN, i could have made my own motorcycle parts back in the day, lol… cool expensive foot pegs… free clutch and brake levers… all KINDS of stuff… this is kind of “fun”, too.

With enough black coffee and cigarettes? all things are possible…

I am currently still shipping… REAL GENUINE CREE xp-g emitters, the classic… brace yourself? as low as 20 cents apiece!! Check out the SALES THREAD, everyone is happy… then PM me

SALES THREAD:
http://budgetlightforum.com/node/52528

if you are into reloading? this is my site… I inherited the remains of what was once arguably the best reloading site on the internet… its the “BLF” of reloading sites…

http://reloadbench.freeforums.net/

if you think night vision would be cool? It IS… this site i am a member of, and its basically the “BLF” of home made scratch-built digital night vision. They are at the leading forefront of advanced DIY for digital night vision, and thats gun mounted or handheld… builds rival and exceed commercial offerings…

http://nightvisionforumuk.com/

Lightbringer
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Maybe a dumb question, but do you have any recycling centers out there? 5¢ deposits on cans? That kind of thing?

I imagine they have to be able to recycle a good amount of Al with minimal waste to make it worthwhile, so if you find such a center, ask for a tour. Show pix of your setup, explain what you want to do, and just say you want to know how the “pros” do it. Even get free advice.

Even bitch’n‘moan about hippies. They smell funny, anyway. Kinda like patchouli.

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old4570
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sedstar wrote:
all good ideas… coolness.

yeah… online i like “backyardmetalcasting.com” they guy made me think “hey maybe i can DO THIS” and not need a degree in metallurgy, lol.

funny thing is, i dont even NEED to be good at the “casting part”, it can come out rough… i am just gonna machine it all off anyways. its all good.

backyard website? has a link to a “forum” like this one, just not nearly as many people into it, though… one guy? said HE was a machinist, and was just “casting machining rounds” so he went with cheap home made casting sand, as it didnt matter, cast it rough and machine it off.

i was like “whoa, thats ME! good deal! thats what i wanted to do!”

=======================================

i bought another 3” pipe and giant endcap today, will get back to a few more ingots tomorrow, i guess. Its just “busy work” to make ingots now, more or less… the more i have, the more “machining stock” i have now…

it will be “a while” before i ever get adventurous enough to try to cast a light body or anything, though, if ever… i’m happy casting rough cylinders to machine on… and its even easier to make a “flat” of aluminum to mill it flat…

i mean, i know about a fingernails worth of all this, but, its WORKING. if i get any better, thats just gravy. i’m content now. i promise PICS when i have some more ingots and make a bigger piece of “stock” up that would actually be a little “pricey” for me to go buy it…

actually? the “mix” cans are made out of? isnt a bad alloy at all…. its okay for machining. i checked… MAN, i could have made my own motorcycle parts back in the day, lol… cool expensive foot pegs… free clutch and brake levers… all KINDS of stuff… this is kind of “fun”, too.

Some alloys dont have great stress strength …
There are soft weak alloys that can do a lot of stuff , but some alloys need to be strong …
One thing I remember from way back is broken break leavers .. ( Weak alloy )

Some things need to be top shelf ( Foot pegs , break levers ) …

Generally the better the casting alloy , the weaker it is ..
Which is why a lot of aluminum stuff is machined / not cast .. ( where strength is paramount )
Casting is great for stuff that is cheap and easy , and don’t need to be particularly durable .. ( Low stress )

 Always remember , the easiest thing in the world to do , is to expel hot air from your lungs and through some vocal chords ..
The resulting sound may , or may not be worth listening too ….

 

sedstar
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all right, i will come out and say it… here i go…

1) every light out there is “aerospace quality aluminum alloy”… which about means nothing to me. ad copy. i mean yes, of course aluminum is endemic to the aerospace industry. whoopee.

2) lies about lumens? “zoomie in” and “zoomie out” make a 5 mode intoa 7 mode? ha2 is really ha1??
now… tell me the light is guaranteed to be made out of 6061 t6 alloy… riiiiiight. couldnt POSSIBLY be a different alloy designation? snicker

3) it is a flashlight. its not a stress point on the space shuttle. its a flashlight… if you machine out a “mere mortal alloy” and its nice and beefy? whats the problem?

4) i figure my machined light i make? will be… “basic” shapes? i am not a master machinist working for boeing…? so, i wanna make up for that basic design? by “going big or going home”. thicker. beefier. bigger pill.

5) i dont know, i wana try to make something you can punt like a football with steel toes, and it just gets scratched, lol…

With enough black coffee and cigarettes? all things are possible…

I am currently still shipping… REAL GENUINE CREE xp-g emitters, the classic… brace yourself? as low as 20 cents apiece!! Check out the SALES THREAD, everyone is happy… then PM me

SALES THREAD:
http://budgetlightforum.com/node/52528

if you are into reloading? this is my site… I inherited the remains of what was once arguably the best reloading site on the internet… its the “BLF” of reloading sites…

http://reloadbench.freeforums.net/

if you think night vision would be cool? It IS… this site i am a member of, and its basically the “BLF” of home made scratch-built digital night vision. They are at the leading forefront of advanced DIY for digital night vision, and thats gun mounted or handheld… builds rival and exceed commercial offerings…

http://nightvisionforumuk.com/

old4570
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Not picking on you …
Post was in regard to Motorcycle Parts …

What your doing is fantastic , …. But there are things that just should not be cast out of soft aluminum ..

I sat in my driveway one morning letting my engine warm up .. ( Motor bike )
I pulled the front break lever hard to test the breaks before going for a ride , I don’t normally pull that hard on the breaks ( But a test is a test )
The break lever snapped like a glass rod .. Where it broke it was powdery and course … ( bad casting ) …
If it had happened on the road , it could have cost me my life ..
The reason I did that .. Broke too many break levers on push bikes …

This is for anyone thinking about casting .. Casting for yourself is a fantastic idea , but keep in mind the application ..

 Always remember , the easiest thing in the world to do , is to expel hot air from your lungs and through some vocal chords ..
The resulting sound may , or may not be worth listening too ….

 

sedstar
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Location: East coast, united states...

so… how would you like a machined brake lever? that would be cool…

With enough black coffee and cigarettes? all things are possible…

I am currently still shipping… REAL GENUINE CREE xp-g emitters, the classic… brace yourself? as low as 20 cents apiece!! Check out the SALES THREAD, everyone is happy… then PM me

SALES THREAD:
http://budgetlightforum.com/node/52528

if you are into reloading? this is my site… I inherited the remains of what was once arguably the best reloading site on the internet… its the “BLF” of reloading sites…

http://reloadbench.freeforums.net/

if you think night vision would be cool? It IS… this site i am a member of, and its basically the “BLF” of home made scratch-built digital night vision. They are at the leading forefront of advanced DIY for digital night vision, and thats gun mounted or handheld… builds rival and exceed commercial offerings…

http://nightvisionforumuk.com/

Tinderbox UK
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Does anybody make aluminum pipe specifically for making flashlights, basically the ID come in various sizes suitable for flashlight battery`s sizes and the ED in various thicknesses to allow different body shapes to be machine out.

 

I suppose this has already been done to save the time on boring out the rod yourself.

 

EDIT: Great thread sedstar.

 

John.

SkyRC MC3000 – Maha C9000 – LaCrosse BC-900 – Floureon BT-C3100 V2.2 – Accumanger 10 and 20 -Thunder AC6 LiitoKala Lii-100 – Cozypony 24W Solar Panel – Soshine H4 – Soshine T2 – Soshine E4S

old4570
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Tinderbox UK wrote:

Does anybody make aluminum pipe specifically for making flashlights, basically the ID come in various sizes suitable for flashlight battery`s sizes and the ED in various thicknesses to allow different body shapes to be machine out.


 


I suppose this has already been done to save the time on boring out the rod yourself.


 


EDIT: Great thread sedstar.


 


John.

Sure .. You can buy Tube … Lots and lots of tube out there , some is dirt cheap . Just think of anything that might be close to the size you want , like maybe tent poles ..

 Always remember , the easiest thing in the world to do , is to expel hot air from your lungs and through some vocal chords ..
The resulting sound may , or may not be worth listening too ….

 

old4570
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sedstar wrote:
so… how would you like a machined brake lever? that would be cool…
A lot of aluminum parts are now machined from forget billet ( For motorbikes ) .. Improved CNC machines have made such affordable by minimizing machining time .. It’s been a long time since I been on a bike , hell I even remember breaking a clutch lever ( I think that might have been on my KLX250B2 from way back ) After that I learned to change gears less clutch … ( Not from a standing start – though it could be done with difficulty ) I think they make carbon fiber parts now .. ( If you don’t feel like entrusting your life to cast parts ) .. So if I were riding right now , yeah the clutch and break levers would be Carbon / or machined forged billet ..

But as with anything , there is that sliding scale from cheap to prohibitively expensive .. ( For things that can kill you when they break = What is your life worth )

Story time :

I used to buy retreads for my car .. I was young and wanted money for other things ! If there is a lesson anywhere , its Australian roads .. They are littered by retreads that have de-laminated .. At this time I did not do much in the way of long trips in warm weather .. This one day I set out before sun up , to go Metal detecting in the Golden Triangle … Was a two day trip .. ( Week end ) The way out was cool .. The way back was HOT … Was about 4pm ish ( The hottest part of the day here ) .. Temps around 36c And suddenly there was a vibration that quickly turned into a spray of something , that turned into a skittish car …. I got the car pulled over to the side of the road just in time not to destroy the rim .. The tired had been completely destroyed ( de-laminated and then self destructed ) Yeah , my very last re-tread … Australia gets hot , the roads get hot , and rolling tires get stinking hot , hot enough to de-laminate ( retreads ) Under some conditions re-treads are fine , under harsh ( hot ) conditions they just might kill you . I dont know why they were ever legal ? Especially when Australian roads are littered with dead re-treads ..

 Always remember , the easiest thing in the world to do , is to expel hot air from your lungs and through some vocal chords ..
The resulting sound may , or may not be worth listening too ….

 

sedstar
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Location: East coast, united states...

here’s me machining the first “dry run” piece of stock i made…

http://budgetlightforum.com/node/53416

still in the “roughing” phase, i’ll skim off lightly when done, to make the tailcap and body fit like one piece.

but, notw this is the “first” and therefore “roughest” piece i made… they come out much better now, stock pieces…

this is working out really well…. i mean, 2” or 2.25” round stock? thats 30 dollars a FOOT… and i can just whip it up for practically nothing on fairly short notice.

next up? i’ll show some pics of the process itself…

With enough black coffee and cigarettes? all things are possible…

I am currently still shipping… REAL GENUINE CREE xp-g emitters, the classic… brace yourself? as low as 20 cents apiece!! Check out the SALES THREAD, everyone is happy… then PM me

SALES THREAD:
http://budgetlightforum.com/node/52528

if you are into reloading? this is my site… I inherited the remains of what was once arguably the best reloading site on the internet… its the “BLF” of reloading sites…

http://reloadbench.freeforums.net/

if you think night vision would be cool? It IS… this site i am a member of, and its basically the “BLF” of home made scratch-built digital night vision. They are at the leading forefront of advanced DIY for digital night vision, and thats gun mounted or handheld… builds rival and exceed commercial offerings…

http://nightvisionforumuk.com/

Lightbringer
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old4570 wrote:
Australia gets hot , the roads get hot , and rolling tires get stinking hot , hot enough to de-laminate ( retreads ) Under some conditions re-treads are fine , under harsh ( hot ) conditions they just might kill you . I dont know why they were ever legal ? Especially when Australian roads are littered with dead re-treads ..

Yeah, here we call them “gators” when they’re lying on the road like that.

Used to see them all the time years ago, but not any in quite a while that I recall. Either lamination got so much better that they’re not littering the road with gators anymore, or no one’s buying retreads anymore. Hopefully the latter.

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