Casting a set of Turbo Manifolds - THE SKID FACTORY [Quick Tech]

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4 жыл бұрын

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Pattern Making and Sand Casting are ancient arts, the first iron casting was in 700BC! In this episode of The Skid Factory Quick Tech we explain the process of modern Pattern Making and Sand Casting with the help of our good mate Danny who is a Pattern Maker by trade.
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Please note: We like to make interesting car mods and show you how we've gone about it, but we can't promise that anything we show you will work for your particular car, or that you won't harm yourself, someone else, your car or your warranty doing it. Please be safe, be responsible and unless you know what you're doing, do not fool around with very serious machinery just because you've seen us make it look so easy.

Пікірлер: 555

@theskidfactory 4 жыл бұрын

Let us know what you would make a Turbo manifold for!

@PaceWorks 4 жыл бұрын

Just in time 🤙🏻👍🏻 Couldnt find anything to watch👌🏻 Turbo mani for 5cylinder Volvo engine used in focus RS to go into Ford Sierra Sapphire 👌🏻🤙🏻🇮🇪 I'm calling it the Sweedish Jz 🤙🏻😋

@alfaholic3 4 жыл бұрын

I would remake the Turbodelta castings for my Alfa Nord or TS engines. If i had my way i would remake the Autodelta 16V race heads from the 70s.

@aposparta 4 жыл бұрын

Single turbo conversion for my Legnum

@TheRealJoshN 4 жыл бұрын

vh45de big spooly boi and build the auto in my Q45

@WickedMachineWorks 4 жыл бұрын

The Skid Factory VW Beatle. I’d make Alan fix the engine too.

@mymistymountainhop 4 жыл бұрын

I'd make a cast engine mount for an sr to mount to the bottom of a lake

@theskidfactory 4 жыл бұрын

Call me.

@lewdog9647 4 жыл бұрын

Why you be hating on the SR? 😂

@mansalans 4 жыл бұрын

@@lewdog9647 I own a silvia with an SR in it, they're awesome when they work, it's just the 90% of the time that they're broken that sucks.

@corinelson7837 4 жыл бұрын

They already make those. The hardware store calls them "cinder Blocks".

@lewdog9647 4 жыл бұрын

@@mansalans does the lack of reliability have anything to do with limiter bashing? 🤔😂

@Colbasaurus23 4 жыл бұрын

Funny how the apprentice becomes the master - Al confidently presenting and hosting the show, giving others confidence. You love to see it!

@krusher74 4 жыл бұрын

he did a great job of translating the other guy's industry terms into more easily accessible pieces of info for us.

@holotropik 4 жыл бұрын

Huge respect to pattern makers and casting fabs. Spent a lot of time designing aluminium castings and sending them to be cast. A true art form 👍😎

@stevearcade 4 жыл бұрын

Love it when you get your trade mates in to broaden the educational elements of the show. This was fascinating to see the inside scoop on what/how this stuff works.

@darryl3392 4 жыл бұрын

Dream casting would be a 8-7 port mini 1275 head with injector mounts in the casting and proper plenum that clears the round noise hood and take a proper throttle body

@boingkster 4 жыл бұрын

I believe they call that either a 1995 Nissan Micra engine, or alternatively a Suzuki Hayabusa.

@brendangallagher8292 4 жыл бұрын

Anybody else expecting glorious music from Al when he palmed each face of the cast manifold?😁

@destinationunknown494 4 жыл бұрын

Would have liked to hear more from Danny, particularly how he goes from a drawing to a timber mould. getting all those dimensions right keeping a proper thickness of metal etc, sounds like an interesting trade, this pattern making.

@BoostedSteak 4 жыл бұрын

4th generation foundryman here and loved seeing this episode. Love seeing proper information about what I do even if I don't cast automotive parts.

@79huddy 4 жыл бұрын

I used to run patterns for Ford lightning superchargers and ctsv Cadillacs them damn things were a process with the white cores that crumbled if you looked at them wrong loved that job my shoulder and lower back not so much we shoveled all our sand and carried are own moulds to the floor

@aSinisterKiid 4 жыл бұрын

awesome segment. Casting is such an amazing process once you figure out how to do it. It's got so many little things that can go wrong, that you just have to learn as you go by doing it. The people who can do it well, are truly artists and craftsmen. There is a science to it and their experience is priceless. Such a great process to learn and understand. Thanks for sharing.

@steveveness3829 4 жыл бұрын

G'day from West Australia, Alan😉 So cool to see some of the process again, and indeed that there is still someone left who knows how it's done. Big double thumbs up for this one buddy. 😉🙂👍👍

@motoxray 4 жыл бұрын

Great skills in making those moulds, very informative, thanks boys!!

@derekharmon8699 4 жыл бұрын

i had a workshop class that let us cast handles when i was in middle school. Great trade to learn and fun doing it!

@alexbrown1995 4 жыл бұрын

My first job out of school was in a non ferrous foundry. In 1970. Smelly, smokey and dusty, not to mention dusty. An OHS nightmare, but the results were very satisfying. My main memory of the place was one of the pattern makers who wore a suit and tie to work every day - his neighbours thought he was an accountant :-)

@mortenbakke2810 4 жыл бұрын

Just a couple hundred meters down the road from the engine factory where I work, our foundry plant is located, where they make cylinder head castings and a lot of other stuff that goes into the engines we produce. We did cast the engine blocks back in the day too, but as the engines got bigger the foundry was too small, but the quality of our "in house" (really in another house) castings are quite formidable:)

@seasnailll 4 жыл бұрын

Skid factory, thank you for putting together this content. Not only did you support your local tradesman, but you shelled out of your pockets to go over the top and provide us with extra learning content. Good lads.

@brandongood8712 4 жыл бұрын

I work for a casting company in the USA, my plant does the grinding/cleaning up. Cool to see the other end. Also we call the thin metal at the seams ''flash', where the metal is poured in is called the ''gate', random chucks of metal are called ''mold stickers'. It is a very involved process. Were actually the company that produces the precision turbo housings. Along with tons of other stuff like borg warner tensioner bodies(for ford and chrysler), 50 cal machine gun parts for the government, loads of farm equipment for john deere/dawn/CAT, the landing gear assembly for semi trailer(we are the only company thats makes them in the whole USA), parts for ventilators(pretty important rn), and crap loads more. Basically if its made out of cast iron, we make it lol, besides brake stuff for insurance liability

@mj_aussie_coaster_travels8310 4 жыл бұрын

Irezel I used to work for a couple of companies that did it. First one was casting taps and valve bodies and similar plumbing stuff. My job was to knock out all the filled moulds and remix the sand. Bloody physical job haha, second job was working for a railway engineering firm that made the major components for trains, and I had to fettle the components to clean them up after casting. A good day at work would have me working on large components where you only knock out 5-6 a day, rap day would have me working on twist lock pins and having to get thousands done a day. So glad I’m not in that industry any more.

@-MacCat- 4 жыл бұрын

Great job explaining the process guys. Yes, please do a session(s) on the lost wax and investment processes as well.

@fibgoldbergfan 4 жыл бұрын

I see a Binky manifold coming soon ;}

@eddominates 4 жыл бұрын

* _leans into the mic_ * *it's entirely possible.*

@darryl3392 4 жыл бұрын

Yes please in come shot Al throwing off screen and Nick catching

@scottinWV 4 жыл бұрын

@@darryl3392 That's one of those "spit my drink all over the PC monitor" events.

@zackrogers9334 4 жыл бұрын

@Viscous Shear I take it you didn't watch episode 30 of Binky to the end

@viperstd 4 жыл бұрын

@Viscous Shear not any more

@aaroncutts 4 жыл бұрын

Love these quick techs, keen to see more in future 👍

@jonoabroad 4 жыл бұрын

That was bloody excellent, thanks folks.

@shark73 4 жыл бұрын

Fun watching the explaining of a industry i make my living in. been working maintenance on a ductile iron foundry for 25 years. here everything is automated, the pouring is laser controlled. Great episode!

@DangerDaveMurray 4 жыл бұрын

Awesome episode! Casting is such a common thing but not easily diy-able, so it's cool to see someone who does it professionally doing neat one-offs

@southjerseysound7340 4 жыл бұрын

It's not as hard as you would think. Brass, and aluminum are very friendly to the home shop using diy homemade gear.l used to help my grandfather cast bronze boat parts with a diy furnace made from a old propane tank and electric leaf blower. It's when you get into cast iron that things get a little more difficult. But it's doable with practice.

@gptg1981 4 жыл бұрын

Poor Danny seems very nervous in front of the camera. Casting process is pretty cool, thanks for sharing!

@GODEES77 4 жыл бұрын

Love these tech vids as much as your build vids. I enjoy the theory and tech side of things, extremely interesting

@wilschell9984 4 жыл бұрын

It is a cool process. I used to be a mold maker. We call the excess seem "Flashing". Wanted to make sandcastle and watch someone try and kick it down.

@keithmartell3971 4 жыл бұрын

I have been casting at home for years, pattern making is the key to success with it. Thanks for the video and I hope more people learn about what casting can bring to their projects. What I would give to talk with Denny for a day and learn just a few of his skills.

@771bjy 4 жыл бұрын

Keep ‘em coming boys!!! Really interesting hearing about the way these things we take for granted are made!

@urdead2meboy 4 жыл бұрын

i used to work for company that die casted and also did hard sand casting and used to use shell cores to make the pipes was horrid job in the foundry but I did it while I was training to become a mechanic . was fun to see this love the videos !

@Leviathan431 4 жыл бұрын

What a fascinating video! Thanks so much to Danny for visiting this channel and sharing his knowledge. As for what I would build a cast manifold for? I hate to be cliche, but I'd love a 2jz-ge turbo manifold for my IS300. That or I'd love to turbo a VR6 Bora one day, those things are so boring looking but sound incredible.

@Turtleism 4 жыл бұрын

Super interesting video that i didn't really expect to see on a monday morning but im glad i did.

@MIX41L 4 жыл бұрын

Awesome video guys, really enjoyed the technical side and unique content cheers!

@jesscneal 4 жыл бұрын

I've done some 3d modeling for a cast manifold before. With the advent of 3d printing, casting complex stuff is getting easier.

@phuzz00 4 жыл бұрын

Plus, if you're doing 'lost wax' style casting, you can just print the piece in plastic and melt that as if it was wax.

@madmick3794 4 жыл бұрын

Bloody love this team, great work and very informative.

@andrewlangford88 4 жыл бұрын

Cool video, something I've never really thought much about casting before

@devjyarn 4 жыл бұрын

What a cool niche. Thanks for sharing!

@tonypinker2884 4 жыл бұрын

I had a mate in sydney many years ago who cast the first five bearing crank shaft for Holden...never really thought much about it until i saw this dude...interesting

@evanjfraser 4 жыл бұрын

Very cool. I did get to do some aluminium casting back in high school, but this is something else! Thanks for edumacating us

@toddmccarter45 4 жыл бұрын

Oh man this is so awesome, I love the idea of casting, and hope to be able to get everything together to do it in my backyard one day!

@southjerseysound7340 4 жыл бұрын

I keep meaning to get my grandfather's casting gear out. He used to do a lot of bronze boat parts and everything he used he built. The furnace was a propane tank lined with cement mixed with vermeculite or perlite from the garden center and it used a old electric leaf blower and propane burner. I remember him making crucibles too, but they are cheap and easy to get now that I wouldn't bother. It's crazy but I kept his old phone number after he passed away at the shop and I still get calls from people who need bronze boat parts for projects. I actually am it thinking about starting to get back into it again because my other work is slow.

@xgford94 4 жыл бұрын

Thank you for keeping up content, your helping to keep me sane, seriously Thank You

@CraigOverend 4 жыл бұрын

I used to fall asleep listening to dad machining dies for aluminium casting on the milling machine underneath my bedroom at night. Now my brother makes his own manifolds with CNC, and is 3D printing an airbox for his ITB Datsun 1600 over the shutdown period, I'm trying to convince him to make a 10kW electric supercharger for forced induction. into it. I'd make a turbo manifold for the ride-on mower I'm helping fix for him. =)

@vincem5 4 жыл бұрын

so good to see people still doing this sorta stuff. dieing trades for sure. regards from a Toolmaker/diecaster.

@jbm3458 4 жыл бұрын

This was super interesting! really good viewing

@jessejohnson9871 4 жыл бұрын

Hey guys, as a tool maker and machinist that has machined many a sand casting, thanks for covering this stuff.

@MrPropanePete 4 жыл бұрын

Love those safety boots (thongs / flip-flops) at 10:38 Perfect for deflecting hot sand or metal

@ThePonkster 4 жыл бұрын

Thanks for explaining that Denny - a very interesting vid - thanks Skid Factory for making that .

@craigsmith271 3 жыл бұрын

I had one of Al's alloy intake pipes on my RS Liberty years ago, bit of porting by a mate and some crinkle paint out of the can and it looked cool and very functional.

@johnp3566 4 жыл бұрын

Episodes like this are why The Skid Factory is the best KZfaq car show out!

@rickshaw393 4 жыл бұрын

I really enjoy these Quick Tech videos. Very interesting topics. Thank you

@gazza116 4 жыл бұрын

very informative,good to see your keeping the distance.

@michaelsidhu4079 4 жыл бұрын

Well done guys on bringing us quality content like this. Al has become quite the professional presenter. Excellent informative video, I am looking forward to seeing the next one. 😊

@g.cooney6599 4 жыл бұрын

Another well presented, fact loaded and fun video on a topic I have always wondered about! Thanks & Stay Safe!

@H3BLTM 4 жыл бұрын

Amazing video! Great insight 🖐🤙

@tayyabsafdar7069 Жыл бұрын

Thanks for all the information and knowledge about casting.

@MaXimus666789 4 жыл бұрын

Awesome vid, cheers Al n Danny!

@Dug6666666 4 жыл бұрын

Yay Pattern Making this is my trade also. If you can 3D model what you want, many pattern shops can use that as the basis for CNC routering the Pattern tooling. Tapers, split lines, core box development, machining allowance and scaling larger for contraction would need to be added by the Pattern Maker but having a model of what you want will save you some up front cost. Your local friendly router equipped Pattern Maker might give you the information you need to to add those steps if they first have something to look at.

@Dug6666666 4 жыл бұрын

Simple parts with no cored hollowed out areas, if they are cast iron in particular (low size charge between cast temperature and room temp) can use a sample part as the pattern itself, with any drilled holes bogged over and for instance lino floor tile material cut to shape and stuck on where extra cast material is needed to machine back later. ie a cover plate. For small run parts there are times when it is possible to cast tapered legs on a part as temporary machining supports that can be ground off later. Hope some of this helps someone. I'm sure the scope of the video was to avoid sounding like a Trade school lecture.

@jamesruralsparkynz3504 4 жыл бұрын

Learnt alot from the video guys, thanks for taking the time to show us 👌 cheers

@mrsmith274 4 жыл бұрын

Awesome episode guys was cool to see the process👍👍

@PawnSacrifice 4 жыл бұрын

A new crossmember - to move the main bar back, the Posche engine mounts much further forward than the modern VW Audi on. AND... you can do this with plastic! Handy for replace broken and worn gears, clips, switches. Great vid, btw.

@stenchcivic1515 4 жыл бұрын

I’m a pattern maker by trade and this was a great presentation of “ what the hell is a pattern maker? “ that I’ve seen. Keep up the fine work fellas, you’re all Artisans at the Skid Factory 👍

@Loztown 4 жыл бұрын

Great Video guys! I now know all the correct names for all the things! If I were to make a manifold, I think I would adapt a Mitsubishi Evo manifold to fit a K20. Twin scroll, with so many turbo upgrade options. Keep the price point low, and give Kswap and civic guys an easy bolt on 2nd hand turbo upgrade. Good for like 350 horses, but with instant torque!

@lukeprowse3215 4 жыл бұрын

Very informative, thanks for the upload.

@stephenmarton7631 3 жыл бұрын

THAT IS AWESOME! I appreciate casting a lot more now

@turps0 2 жыл бұрын

Very interesting video guys! I would've liked to have seen more on how the core is supported inside of the mold (as it has to essentially be floating )

@herbgaming7852 4 жыл бұрын

Awesome video guys 🤙🏿 Keep up the awesome work in these unique times. Stay safe homies 🤙🏿

@scottinWV 4 жыл бұрын

I love this channel! I gain tremendous knowledge and have a laugh while at it.

@graemesmith1965 4 жыл бұрын

That was a very cool video so good to learn more about our passion in cars

@ryanhacker9444 4 жыл бұрын

Awesome content!

@bostedtap8399 4 жыл бұрын

Molten metal, Yes!!!, Possibly earliest method of 3D manufacture. Great vlog guys. Stay safe all and thanks for sharing.

@dartology 4 жыл бұрын

An interesting topic. Thanks for that guys.

@experienceoutdoors6279 4 жыл бұрын

I used to work in high pressure die casting certainly a expensive set up cost dies made in Australia range 20,000-500,000$ but if maintained will last 5 Millon of parts or so. Used to make all of the cast alloy ford and Holden parts.

@mf90quip 4 жыл бұрын

I love this type of content, thanks.

@brucebrucestofiston5554 4 жыл бұрын

Thanks Al, that was interesting.

@malcolmyoung7866 4 жыл бұрын

When your tool box is perfect to maintaining safe ‘social distancing’. Cool video...looks like everyone needs a ‘Denny’...

@fredericrike5974 4 жыл бұрын

The Kensington Gardens in London was the largest cast iron framed building in the world when it was built in the late 19th century, I think. The technology has gotten more refined, but is still recognizable. Lost wax is the key to very high precision casting- that and techniques for introducing the molten metal under pressure- but suddenly very accurate pieces with little machining are possible.

@kiiiisu 4 жыл бұрын

very interesting, thanks for the video

@MrCybergladiator 4 жыл бұрын

Good video, keep up the good work!

@sjion 4 жыл бұрын

Great video boys!

@nickshamla347 4 жыл бұрын

to see some good diy casting a good channel is myfordboy, makes his own patterns from both wood and 3d printing.

@ma61king 4 жыл бұрын

Nick Shamla olfoundryman is even better, the guy explains absolutely everything and even shows how me makes his sand - his castings come out super smooth too

@nojhampton 4 жыл бұрын

I enjoyed casting my eye over these tech bits, but think it would be easier to understand if Al wore a white jacket ( with pens in top pocket) and thick rimmed glasses!

@nedyahyakcam 4 жыл бұрын

So looked like Jason from engineering explained

@donkkillag8435 4 жыл бұрын

pure gold keep it up lads

@markwng 4 жыл бұрын

I used to work in a factory that had a foundry and a machine shop.. Interesting business

@RandBLSWorld 4 жыл бұрын

Cool stuff ! Great video Thanks !

@MrWilliam.Stewart 4 жыл бұрын

Thanks for making

@John-td9cp 4 жыл бұрын

Appreciate the content!

@davidorama6690 4 жыл бұрын

Your channel is fantastic.

@phonzy 4 жыл бұрын

Excellent!

@jongroom2954 4 жыл бұрын

Interesting episode thankyou.

@rjl110919581 4 жыл бұрын

thank you for detail video use work in that area as use in build of electric motor industrial in Australia

@a_Fax_Machine 4 жыл бұрын

I'm planning on mocking up a manifold to put 2 Weber DCOE-style EFI throttle bodies on an oval-port Ford 2.3L Lima. I hadn't thought about casting it, but that would be a great way to do it.

@ClearComplexity 4 жыл бұрын

Casting wise I've done some of the lost-wax casting myself to make a couple intake manifolds for a Vortec 4200 since we didn't get the Barras here. I got a 92 E36 Coupe that had a 1.8L with 230k miles, figured why not use the 4200 I had (the answer being making it worth with a manual gearbox...I can machine a flywheel and make it all work but I'm really closed to making it a automatic to avoid the hassle) laying around and turbo it. As for Beats, I've kept mine completely factory more the most part, the Cappuccino on the other hand...By the time I got it needed a little bit of a refresh so I went a little too far out for a Kei car and ended up using a LNF out of a totaled Sky Redline along the rest of the drivetrain pretty much. It all just fits and even stock with a tune it's a nice little death trap.

@donkeyha6053 4 жыл бұрын

I wonder if there is much plastic moulding left in australia, would be cool to see all the different kinds. Ive only worked on injection, blow and compression moulds.

@Wood-Renovations 4 жыл бұрын

11:15 thank you Al for reminding me (an American) how fortunate and blessed I am to have been born into the life and opportunities that I have. Never take it for granted!

@jamestehuna5915 4 жыл бұрын

To be honest a lot of the old Skiddys content is really interesting but this was fully sick I’ve always wanted to know how it was done cheers great content

@magnus.nasmark 4 жыл бұрын

Fun fact. I did lost wax casting in art college. It was involved, hot and slightly dangerous. But very rewarding.

@Procharged32 4 жыл бұрын

Excellent video lot a work suppose thats why a lot of people fabricate with stainless pipe, thanks for making this.

@DaveyGa 4 жыл бұрын

First saw a pattern maker's workshop at the old Yarloop Rail Workshops, hundreds of intricate wooden pieces including gears n stuff (sadly it all got burned in bushfires a few years ago :( ). Almost a lost art nowadays, onya Danny, respect ya skillz.

@pug2o5 4 жыл бұрын

The How to heat wrap should be made into a quick tech - from the twin turbo LS VK build. I wish I had that info back when I heat wrapped my Dump pipe

@araml.3138 4 жыл бұрын

Will you do a quicktech on the other casting processes, it's quite interesting!

@LENSX_NA1 4 жыл бұрын

K-swap in a Honda Beat, that’s something I’d love to see. Honda Beat is an awesome car, could just use a little more power

@PaceWorks 4 жыл бұрын

Icetronics in Ireland put one in a Honda jazz and took it racing.

@ef7andapp170 4 жыл бұрын

40 extra HP and a taller final drive would be great!

@cymans1164 4 жыл бұрын

Or the s660 the modern one

@hendrahendra 4 жыл бұрын

Had a mate who attempted that idea, poor little car's chassis railing had to be chopped, it looks like it compromised alot of its structural rigidity. Stick a hayabusa engine in it may work better.

@EatMyYeeties 4 жыл бұрын

I've wanted to do this for quite some time! I've been between that and Gsxr 1000/1300 swapping a Cappuccino.