This 79 year old Gearhead is learning a lot from this young fabricator. Thank you.

This installment definitely took me back to my Foundry & Forming course, back in my Uni days as an Industrial Design major, 20+ years ago. We did hands-on small-scale projects using green sand casting with reusable molds,as well as lost-foam casting; this was accompanied by field trips to a couple of foundries in Northwestern Washington State, that produced items like massive propellers for commercial vessels, which was really amazing to see. IIRC, when we used the lost-foam process in our own lab projects, we first coated our styro masters with a ceramic slurry (that was either air-hardened or fired before the next step). The master was packed in sand/clay, then cast. All I clearly remember is that I had attempted to do a mold for a cast trivet, that didn't survive the process, likely because it was not substantial (thick) enough. I'll confess that I'm a bit envious of all the equipment that you have at your disposal. I've been away from all of it for so long, that I wish I had a means to try my hand at it again. Keep up the the great work on this project - you continue to amaze and impress!

Are you sure your not an old man wearing a body suit.for all the knowledge that you show in every video,I cannot comprehend that your as young as you are.always impressive.👍👍👍😎😎😎

You never cease to amaze me.

Only good thing about this corona stuff is that we get more of your videos!

Wrong foam,wrong sand but your castings came out alot better than I expected.

Probably a million different ways to do something and you decided to try something new some people may say they did not come out perfect maybe they didn't but you learn something and so did we thanks for the videos I am very much enjoying seeing you build a car from scratch

This 'have a go' guy is completely fearless. I'm not speaking about handling hot metal... but of approaching tasks which would daunt many fabricators. These videos document him being willing to try out a number of new ideas... and being willing to re-do them when they don't succeed. Kudos.

You are the only person I think that is doing a project like this. I was inspired when I watched a documentary about 1920s racecars and how they're built and wondered if anyone was building one. Then I found your channel and for the last 6 months I've been watching your videos and I'm about to start my own project. I already have a matching engine and transmission and I'm teaching myself to weld and work with metal so I cam make my dream a reality like yours!! Thankyou for making these videos you are one of a kind !!

The intellectual challenge far outweighs whether or not you did it "the right way". Well done sir.

If you want to do more foundrywork in the future, you should definitely watch Oldfoundryman’s channel. Top level stuff and he knows what he’s doing (unlike most of what one gets to see on YT). Loving this series as always!

By far my favorite channel. Wish you were a full time youtuber! this cars gonna be in museums for lifetimes

When I did it in college at PSU, we used a dry sand, and vibrated it against the foam mold, and a bit more sprue. You can see the 1/32 beads. May be worth trying.

It makes sense that a denser foam would help give a better mold surface, but who knows if would effect the casting. Fortunately for you, you selected a router bit that matches the profile of your square file. They turned out aces!

Love this so much! I have long been fascinated with aluminum casting and have done a small bit myself. Most videos are just melting and making ingots or silly costume stuff. I think it is so much cooler and more fun to make actual useful parts for a project like this. May I suggest you knock together a simple hot wire cutter to make your foam patterns?

When you are involved with making anything from scratch, you go where it takes you to make the parts. That is what is so interesting about making things. You learn whatever skills needed to get the job done. Thumbs Up!

Absolutely awesome job!

Nice, such a simple but effective technique, the car is looking amazing.

I like that you did not take the easy route and just mill them out. This is the way they would have been made in the 20s and gave you a great opportunity to learn about a lost art form! Awesome job!

Great skills being shown, as always.

Awesome work when I used to work in the foundry during uni breaks I used to use blocks of wax to cut and sand the aluminium. Awesome work

I love this channel!

Great work once again

I'm impressed with your knowledge of all kinds of stuff! I subscribed!

That was so cool! I definitely have to try this in the future for one of my projects now!

This video gave me the push I needed to pour my first cast. Thank you.

Giving true meaning to the term "Home-made" Fantastic as always. Always raising the bar

Another Great Video! look forward to the next one!

Cool project and well explained with great video and narration.

wow that was a really great video sand casting made so easy was cool.

This was brilliant bro very good

Those turned out great.

That was a great video. Thank you .

Nice work, love the shape. The only thing I would add is to mount the screws from the back. Drill and tap the aluminum in the back to leave the front of the pedals clean with an uninterrupted diamond pattern. Just my 2 cents.

Putting them used beer cans to use! Awesome video, you are getting so close to the finish line now.

Definitely have to try that. I’ve been wanting to make a brake pedal to match my old school moon gas pedal in my falcon. Now I feel much more confident

GM has used lost foam for engines. The first Saturns looked like a mock-up engines as you could see the bead pattern from the foam

Great work man.

Excellent work as always. I was pretty amazed at the quality of the casting after cleanup - I was expecting it to be more porous but it looks like it was a good pour all the way through.

Great job!

you could rout this right into a flat plate of aluminium on your router table, ive routed aluminium with a woodrouter before and it works quite good. makes hell of a noise but works :D

Just watched the video, Great stuff.

Great video!!

Those look so much more period correct with the slight flaws than if you had machined them from a solid block.

This is super badass!!!

Enjoyed..... I hit the like button.

Nice and very Cool 🤙🏼

So talented

Keep going, looking sweeeeet.

Great vid, but in making the mold perhaps consider making a hot wire cutter with a battery charger or just a battery? You would get far cleaner cuts. Love you work.

Great Car 🚘 Project ❤️

Nice work

Never been first for the upload going live! woo!

Nice idea

Awesome. Thank you.

Nice job, thanks.

Your AMAZING.

I thought most people use that insulation construction foam thats smooth and not bubbley? it seems alot easier to work with and cast smoother

very cool. you could use your mill to also make this out of whatever metal you want.

you should put a small hole on the edge so the air can escape as your pouring the aluminum.they turned out great

I know right, next on micro machines sand casting new engine block. Keep up the good work.

Always good , 🍻🇨🇦👨‍🏭

Wonderful --

I like the audio on this video!

damm excellent - I did some sand casting in Jr. High - bet they don't teach that anymore 'in a world where most don't know which end of the screwdriver to hit with the hammer

Almost 120k Vince....Give us some love and care!

So you just happened to have a furnace lying around. Awesome

This is fascinating. Great technique. I wonder if this would work with metals with higher melting points like maybe brass? It'll be interesting to see what you cast next. Keep it up

Félicitations de france 🤘🤘🤘

excellent

I really love your vids,this is a great project I like to follow.What I was thinking : What are you not able to do? Thumb up from France

Could you now use the 2 halve mold type casting & use a cleaned/refined pedal shape to make the molds? Great video as always.

Cool!

Looks Great! Where did you learn so many skills?

Please find a better way to hold the molten metal rather than multigrips, if you drop it your skin will disappear as fast as that foam did

That was pretty cool 👍 Just kind of wish you had tapped them from the back to keep the surface clean

Nice work, but I would have tapped the back side of your Beautiful Cast Peddle, thus keeping it looking better...IMHO...

Amazing work as always!!!! How about Balsa Foam rather than the bead board??

Hi Mate, its grate that you are applying new trades to your build, however I was wondering why you didn't just machine the diamond pattern into a piece of aluminum plate.

Slick

During the time until the foam was cut out, it was possible to do everything on the milling machine.

Maybe try diatomaceous earth to blend with your sand? You can get it in 50lb bags at feed stores for about 15 bucks.

you should put the starter button by the pedals

I would have cast them slightly oversized to allow for clean up of the back and edge surfaces.

Great job on the casting. Hopefully you have small feet as it looks like it will be pretty tight in the foot area. The car is sure coming along nicely.

I guessing your dad's investment, in all the right tools have paid off..This, in more ways than one, in spades...Kudos, to your father!

I did some casting in high school

Make one out of lead for 5he gas pedal

Coat the out side of the foam with plaster of Paris let it dry then place in dry sand

Try and use finer foam - for example the green stuff used for plants as it has much finer grain and it brings out more detail while it melts away anyway.

If you had cut 1 groove going 1 direction then another 1 the other direction before moving your fence it would go a lot quicker.

It looks as though you made the welded steel container you used to melt the aluminum in, and used it without any sort of coating on the inside. Iron and steel are soluble in molten aluminum and enough will be picked up, even in the short time it's in contact during melting, to mess up the metallurgy of the castings. (Iron dramatically reduces the ductility of aluminum alloys) Your pedal pads might work perfectly well in your application, but if you ever cast any parts that are structural, you really should obtain a ceramic crucible, or at least coat your steel container with a ceramic mold coat slurry. You can obtain either of these from a foundry supply outfit. Also, you appear to be using scraps of aluminum plate for melt stock. This is also probably okay for your pedal pads, but again, the metallurgy of wrought aluminum is formulated to optimize the forming process. You'd get better results using ingot or scraps of sand or permanent mold alloy castings, as their alloys are optimized for the casting process.

Hey Sir. Are you going to post any video's this year? Waiting on the results on the speedster that's all. Hope everything is good with you. take care.

havent sen this type of casting sand before , was supprized the water in the sand didnt cooked off when you poored hot metal intoo it but it worked fine it seemed next project the gas pedal ?

👍👍😎👍👍

Hey Sir. I have one question. Is this a 4 speed? The reason I ask is because their is only two pedals. Or will it be an automatic? Maybe it's just me being dumb. Sorry about that. Really liked the video, I actually learned something. I didn't know how to do forging. Now I can do that. Thanks again. Take care buddy

What’s the difference between being cast or being machined from a billet?

Are you coming back?

For every pound of mold material you use, add 1 tablespoon of 2 stroke oil. It makes the finished product much nicer, and I've been told it even reduces porosity.

You should watch ''Ivans Shed'',Ivan Dutton legendary bugatti builder