Bronze Casting for Boat Builder, Cleat Casting S2-E57
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- čas přidán 6. 09. 2024
- In this episode of The Art of Boat Building Bob Emser, Boat Builder, takes us through the process of casting a bronze cleat. If one where to take "Bronze Casting for Boat Builders" at the Wooden Boat School the first project would be to cast a bronze cleat. Inspired by the classic Herreshoff cleat Bob make the first casting for the Haven 12 1/2 a cleat. Follow along as for the making a wood pattern, investing it in green sand, pouring the bronze, finishing the casting and installing it on the boat.
“If you’re going to make it, make it beautiful.”
Bob Emser
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Carvel Planking Playlist:
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• Season 2 - Haven 12 1/2
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#theartofboatbuilding #artofboatbuilding #makeitbeautiful#woodenboatbuilding #buildingasmallboat #buildingasailboat #shipwright #toolbuilding #Haven12 #herreshoff #shipwright
This is a great job going through the motions and not saying a word. I was drawn in like when watching a good movie. Also the PPE you were wearing was spot on. Thanks for sharing this with us.
This isn’t a boat builder, he is an artist that builds boats and his boats are his art!
Exactly my thoughts as I watch his videos. I enjoy watching many of the boat builds out there but his is different in that its not only functional, it is a work of art. I enjoy watching his process in getting to the final result.
Yeah boats can be art
Had to rewatch this with my coffee this morning.
That was exciting watching another part of art taking form. Isnt it rewarding building and creating things from one medium to another. You just released a cleat from inside the Bronze nuggets. Sweet!
Aside from the amazing skill and craftsmanship demonstrated, the video itself was perfectly edited and presented. I so very much enjoy your projects. Thanks !
The silence in this video was wonderful. Only the sound of the wind against the sides of the workshop. I felt as though I was in the workshop with you. Thanks for not breaking the spell with superfluous music.
The beauty of perfection! Great chapter
Bob: You brought back wonderful memories for me of pattern making and foundry work when I was in highschool. I can no longer use my arms and hands so I'm living vicariously through you. Thanks David
David
I went to Hutch Tech H.S. In Buffalo, NY back in 1967 thru 71. We had semesters in both pattern making and foundry back then. We did traditional sand casting. Never thought twice about it back then but these days can you imagine the parents coming unglued and the lawsuits and attorneys that would be coming out of the woodwork. I wonder where you went to HS school. There couldn’t have been many like them.
Just have one word..Awesome!
Bob, that is wonderful. You're a renaissance man. Thank you.
Wonderful. Could you possibly show us the lost wax technique please?
I have been invited to cast with the university class next semester. If so I'll show a more details video of the process.
In the mean time:
czcams.com/video/PchlWAoDxnk/video.html
Cheers,
Bob
Bob, another fine video. It was very enjoyable to watch. Your attention to safety is very commendable. One safety concern registered with me. After you poured the mould, you got down on your knees to pour the bronze bronze into the scrap tray worried me. For a short period I worked in the foundry at Boeing Commercial Airplanes. The methods used were very much how you do it. I witnessed a 20# crucible of molten aluminum get dropped and spilled on the floor. Not something you forget. People were within the spill radius and everything flammable within the radius caught fire. Even the workers shoe soles caught fire. Fortunately everyone had heavy sole shoes on and were not hurt. Please continue making these videos. I marvel at your skills. THX JimP
Hi Jim,
I do know better than to get down on my knees. The first casting I got a bit caught up in the HEAT of the moment (pun intended) Thanks so much for the reminder and your kind comment!
Cheers,
Bob
Also suggest a table so your mold is at a good pouring height. Cinder blocks are cheap.
How interesting. I really, really enjoyed that.
It is a pleasure to watch you create, very relaxing
Even though I’ve seen him do it a number of times, I still have to watch it every time. Lol
Fantastic episode.
Beautiful work!
What a great video and no music. just goes to show you don't need that terrible music to present a fantastic video. Thanks for taking the time for giving us an insight into casting.
Awesome process, thanks for sharing your journey.
Beautiful piece of work Bob, well done, having worked in the heat treatment industry years ago, it was great to hear the "music" of the furnace roaring away in the background and watch you with the mold. Best wishes from the UK
Dear Bob, I have looked at several people who do casting but without a doubt yours is the slickest operation of them all. The tools you use, like the cradle for your flask is the best looking with that locking triangle on top to secure what could be an incredibly dangerous event of a molten metal spill if it let go. It’s just like all your work, methodical, precise, un-rushed but in the end magnificent.
Bob, you’re truly an artist bud. Thanks for your time yet again.
Very interesting episode. All the best for the new year. 🇨🇦
Super Bravo ...!!! félicitations, c'est superbe...!!
Thank you Bob for the quality time of your videos.. top of the top.. Merry Christmas and a sweet slide into the water with your beauty during 2022.. fair winds always from Switzerland
Your masterful craftsmanship is always a great pleasure to watch. Thank you.
Glad you enjoyed it
Thank you for sharing your skills. Very impressive workmanship throughout this build. Joe
Amazing work, you can be rightly proud of that! Thanks so much for showing us the detailed process.
You are an artist and this is one of the best channel in CZcams!!!!
Beautiful boat jewellery. Thanks for taking us through the process. 👍
Bravo!
Thank you Bob! Waiting for the Next video!
Great video Bob. The cleat is certainly beautiful. Thanks for sharing!
Enthralling from start to finish and a beautiful result!
Amazing! I’m appreciative of an artist making something with their hands instead of a CNC machine. Thank you for sharing your talents.
That was a lot of work but it was for a large reward. It is a beautiful cleat. Thank you for sharing. Have a wonderful new year and stay safe.
Fantastic.
Amazing! I was trying to see if I would remember the steps from my single casting project in school. You have it down to a science with your past experiences. TRUELY AN ART!
WOW!
Outstanding job on that cleat. Very nicely done.
I wondered why you had to split it and then it made sense. Looking forward to next episode.
Mint!! Great video, keep em coming!!
Wonderful to watch so many skills come together to make a beautiful piece.
This was an episode I was waiting for. Wow, I am wow’d!
Watching you over the past couple of years has been great. This episode, with its background shop sounds, spoke volumes.
Thanks Bob, your work is truly beautiful.
It is always inspiring to follow you in the process and share all your experiences. I grew up on the Swedish west coast and like to compare differences and similarities in boat culture. Small boats here were simpler built mostly in pine and hull with overlapping boards, but which gave a beautiful sound when they were moored. Today, that sound has almost disappeared. However, I wonder why the floor is screwed on as it becomes difficult to clean underneath and get all the rainwater out. OK the boats here were in the water most of the year. I remember how they in the evening with calm water ,rowed out a bit on the fjord to fish cod and mackerel, and how they talked quietly between the boats while the sun went down behind the mountains.
Now I know it really is Xmas! Thanks, Bob, and the best of new year's to you and family.
great stuff
This was a fun vid
Thank you
THANK YOU!! I've been PATIENTLY WAITING for this episode. So thank you, Bob. I knew it would go so flawlessly. Amazing and beautiful.
Seeing him hold the cleat, a ruler, and a pencil with 3 hands was pretty funny.
... Cheers...
Yester day i made sand casting aluminum cleat it's fun process
Congrats, we’ll done!
Wow. I am always so impressed by what you tackle and achieve; bravo...and thanks...rr
Beautiful cleat! Enjoyed watching the process. Thank you Bob. Take care and Happy New Year.
Really amazing work, Bob! Beautiful piece! 😃
Something I've learned from a bike customization community here in Brazil is that you can spray some clear varnish over the piece, so it stays shiny for much longer. (But here they used to do it with aluminum parts.)
Anyway... Merry Christmas, happy new year and stay safe there with your family! 🖖😊
Well done Bob. You make it look so easy. Best wishes for the new year!
Marvelous work, A pleasure to watch!
Very good work! It's simple and beautiful!
Terrific work Bob!
One down..
Best wishes for 2022..
The gentleman is an artist and a teacher who should be treasured. I so much enjoy his videos. Now with that said, what is the economic justification for not just buying an 8" heirshof-style bow cleat off the shelf?
Hi James,
Thanks for the nice complement. In the current (Dec. 2021) Haven/Herreshoff catalog from J.M. REINECK & SON ( which make exceptional quality castings) A 7 3/4" cleat is $238.00 Here is a link to the catalog.
www.bronzeblocks.com/pdf/12.5catalog.pdf
If you are only casting one cleat there isn't an economic justification for casting you own. However, if you casting all the bronze for a Haven 12 1/2, as I'll be doing, the full set of bronze hardware is $7,685.00
I really enjoy the casting process. The start up cost and experience that is needed makes it not a practical process for everyone. My goal in presenting bronze casting is to give the viewer an idea of what goes into it. For some it also validates the cost of a hand cast bronze cleat.
Most all boats have bronze hardware. As I build future boats I'm excited to cast the bronze for them as well. I have an idea to cast a 10" bronze dock cleat and maybe a bronze anchor!
Lots of fun ahead.
Thanks so much for your question. Perhaps I'll include it in the next episode.
Cheers,
Bob
Nice Job Bob..looks beautiful.
another excellent video, Bob. Thank you, and merry Christmas!
Yes! I've really been looking forward to this episode.
Great job Bob ! Turned beautful.
Wow, U r highly talented! Great vids! 👍 Been subscribed since I binged the Herreschoff Haven 15
Exciting to see all this come together so beautifully.
Beautiful work as usual, thanks for sharing
Simply amazing!!!!
A very good job to make this new cleat. But the need to have a split pattern escapes me, the world has been casting around one piece patterns or even originals for ever.
Just beautiful. Bob, for those of us new to casting ... given the importance of strength in a cleat, do you have any tips about checking for subsurface faults? X-rays perhaps, or tapping as the experts used to do to railway wheels? I'm completely guessing (as you've no doubt guessed). Thanks for another of CZcams's great maker videos.
Отлично! Какой состав формовочной смеси?Мне приходилось заливать быстрее что бы расплав не остыл Не больше минуты Но формовал в песке с силикатом
Его называют зеленым песком. Это кварцевый песок с бентонитовой глиной и водой.
Parabéns pelo trabalho.
These days you could model that thing in a CAD package and then 3d print the pattern which could either be used in a sandbox or lost wax / PLA cast in plaster.
Hi Bob great overview of the whole process. I wonder if you left the mold pre-heat out of the video, or if you skipped it entirely.
Would be cool to see a “lost foam” type casting. You did mention you have more parts so i hope im giving you a good idea.
This whole boat series is coming out great congrats!
Bruno
Hi Bruno,
There is no need to preheat sand molds. Lost wax ceramic mold are a different story.
I most likely will not be doing lost foam. It requires a new pattern for every part. I did lost foam during my residency at Scana Steel in Norway. One of the big problems is the toxic fumes from the burning foam. Not something I want to do in my shop.
Thanks for watching!
Cheers,
Bob
watching this episode Ive learnt bronze hardware is cheap and casting my own is out of the question way to much time
Hello thank you for the great videos. Can you suggest a bronze foundry ? 😂
Port Townsend foundry in WA they do great work. Ask for Pete
www.porttownsendfoundry.com/
@@TheArtofBoatBuilding thank you
my calm has been missing you ....please re film your creationn
Well, that's the thing about single man operations like this. We get what we get as he puts it out. I'm sure he has a life apart from making this boat.
see you all in a month, or two, or three, or four.
hola el video está muy bueno:👌
🤜🤛👍
Bob, beautiful as always! Do you think that aluminum would be strong enough for a cleat?
Most likely. It really would depend on the alloy. I know of some marine fittings that are cast in aluminum/bronze.
Cheers!
Bob, Nice work and helps me understand why the production stuff costs so much. By the way, seems like the lost wax/ceramic method would be quicker? But it's not repeatable with that same plug?
thanks a lot, Glenn H.
Hi Glen,
Indeed, I just checked the current price of a bronze cleat.( $238.)
All of the casting processes have their pros and cons. Sand casting is the most economic in terms of cost and time. However, is limited in not making complex shapes. This is why most artist like lost wax as they can make any shape no matter how complex. They are generally making only one copy.
The down side of lost wax is the expense in equipment and time. In addition to a furnace, a kiln to burn out the wax and vitrify the ceramic shell and a sandblaster to remove it are needed. The ceramic slurry in very expensive and must be agitated daily. The process of making the wax pattern, dipping in slurry (several days), burnout in the kiln (one more day) and the break out (like removing a coffee mug from the casting) and the sandblasting (one more day)
Most all boat hardware are simple shapes. Once a pattern is made it can be invested, cast, and cleaned up in one day. So sand casting is much more efficient for a small shop and is how most all commercial casting are produced.
I've been invited to cast with the University next semester if so I'll show the lost wax process in greater detail.
Thanks so much fro your question and thanks for watching.
Cheers,
Bob
Thank you Bob for this beautifully instructive video! Did you mount a backing plate on the iside of the deck under the cleat?
It is beautiful!! It seems you have invested in quite the casting equipment; Do you plan on doing a lot more work, or is it some stuff you had around or "just wanted?" DD
Hi Dennis,
I taught casting at the college some 30+ years ago. I have equipment from back then. I really enjoy casting and thought what a great way to get reacquainted with the process than to cast the bronze for my Haven.
Thanks for watching!
Cheers,
Nice! Did you make the pattern larger to account for the shrinkage of the bronze? Or, was 1 to 2% not enough to worry about on a part that small?
Any shrinkage is almost undetectable. With all of the parts for the boat there is not a need for any tight tolerances.
Thanks for watching.
Cheers,
Bob
Do you know the recipe for the bronze you bought for this project? Whoops never mind I see you have it in the next video.
The bronze I use is Silicon Bronze. The alloy is discussed in detail in S2-E58
What did you put in the foundry just before returning the crucible (just after the pour)?
I put a piece of wet cardboard on the plinth. This creates a layer of ash between it and the crucible so that they won’t stick together.
@@TheArtofBoatBuilding Thanks for getting back to me. Just found your site and it's great!
please, you can building a primitive Gatling gun (1876)?
😅
I notice you don't show how you split the cleat down its length. Did you not film that, or was it a case of "commenters can't yell at risky cuts if they don't see them?" :) I'm legitimately curious how you chose to make those cuts though.
Bandsaw
I wondered about that too.
He said he had only glued the ends of the two pieces together, so when he cut the ends off, presumably they were nearly separated, or enough so that a blade and putty knife finished it. A saw kerf, even a band saw, would take off too much material for a good mating
It was two separate pieces of wood to begin with. He did not have to cut it in half. He only glued the ends together of the two pieces before turning on the lathe. So, when he cut the square blocks off the ends, the halves came apart of both the long part of the cleat and each leg.
@@thomasarussellsr that's or
I do not recognize the cutter you used for the recesses in the sides of the cope and drag. Can you provide any info?
Hi Steve,
That is a forstner bit. Nearly every hardware store or home centers sell them. I believe the one I was using is a 2” bit.
Thanks for watching!
Cheers,
Bob
@@TheArtofBoatBuilding Thanks
I feel spoiled doing patterns like this digitally.