This is a level of understanding and patience most people would never have.

I'm 64. In high school, I had a semester of metal working. Part of it involved foundry work. We used simple existing proven patterns. We poured aluminum. It was interesting. Even simple patterns aren't always simple. I really appreciate being able to see how Clark goes about complicated molds. There are those who do and those who criticize. Until you put your hands in the sand you'll only ever be a critic, and a piss poor one at that.

The original Capstan would have been made in a similar work shop in the early 1900s in England using virtually the same tools and process.

This project is Intensely interesting to me. I’ve machined a lot of castings but had very little knowledge of how they were made until I subscribed to this channel. I have a keyboard but don’t dare comment while I’m holding my breath. Thanks so much to Clark and Steve for sharing this fascinating casting process with us.

I am speechless! No doubt in my mind that the capstan project wins the perseverance award for the single most arduous task in bringing Tally Ho back to life. Can't wait until the next Windy Hill video - success finally!

Really enjoyed your starting explanation. You have a great presence on the camera, Steve.

I am a Tally Ho fanboy and would just like to thank you for all the work you guys have put into this. Building a beautiful boat like Tally Ho takes a lot of blood , sweat, tears and craftmanship\artistry.

Sometimes even the power of positive thinking isn't enough. I wanted to believe it was good. But as soon as Clark made his comments I knew. WASSUP Leo and crew!! I cannot WAIT to see y'all install this incredible piece of art. Every single video is SO DAMN GOOD!! Thank you so very much, Clark. The owner of a GD REAL FOUNDRY!! Why would anyone doubt Leo's decision to leave this in VERY CAPABLE HANDS?? The KZfaq commenters keep slipping down the worm hole. Absolutely brilliant stuff.

Appreciate the time you spend explaining to all the backroom foundry experts out there how things are done in the real world. A great video, and looking forward to pour four.

I admire your restraint in addressing the absolute stupidity of youtube basement dwellers. The skill of the craftsmen is in their hands and mind, such as you, not in how much is paid for equipment, facilities or what you call your tools. I’m sure the inanimate tools doesn’t care either. Great lathe by the way.

Thanks Steve for explaining how complicated (and interresting) this process was. And I can't wait for each new video each week.

They way you do your work to me is amazing and I have never seen casting from so close as in these videos. Bigger is certainly not better to show people how casting works. Keep on doing what you guys are doing and above all don’t make excuses because at your age you know what you’re doing. Explaining what you’re doing is greatly appreciated. 😊

Thanks Steve for all the explanation of the details of what Clark had done to prepare the mould, ram it, and extract the mould, and prepare for the pour gave great insight and context to the work involved to make a one off part. I am glad Clark asked you to film and present your point of view of the process. Your collaboration made a very informative and entertaining video. I look forward to the final installment. Thanks for sharing!

I spent a whole semester of foundry shop class in high school learning how to pack a flask with green sand and a pattern. Seems like it took most of the semester to be able to turn the flask over and extract the pattern from the mold without dumping all the sand on the floor.And those exercises were with simple high school project items. The result was cast with aluminum, not cast iron and we weren't allowed to participate in the pouring, the upper classmen did that. I cannot imagine how hellish it is dealing with crucible of liquid cast iron.I also spent two prior semesters learning the rudiments of pattern making. It isn't so easy, even for professionals and Clark is a professional. Seems like there's a lot of armchair riders shooting off their keyboards without much understanding of the issues involved here.

These guys are real craftsman. There’s no bullshit about them. They know what they’re doing and they got a great foundry. And they know how to work it👍🇺🇸👍

The black art of sand casting is full of surprises.!

I hired a drywall finisher a while back. He came into the room, my soon to be son’s room, and heaved a sigh of relief and said it would be an easy job. On the previous job the homeowner used every scrap of drywall to piece together the wall. I used full sheets on the walls. He said the guy saved five bucks on Sheetrock and spent fifty dollars on taping.

Great video Steve, awesome of you to spend your time on such a great project.. thank you.

Any armchair slob with a keyboard can hurl unsubstantiated comments on how to mold and cast metal. But only doers like y'all figure out how to do it. I learn more about the process with every video and I'm grateful for your sharing it.

It just shows in this world today that nothing goes to plan , if it was easy everyone would be doing it so good luck I enjoyed to process and how much work really goes into making it thanks guys n gals 😊

He must have the patience of Jobe, I dread to think what a casting like that costs, whatever it is he earns every penny of it. Can’t wait to see the finished article. Thanks for sharing the process with us.

Getting it right is always a time-consuming learning curve for most new things. Patience and attention to details is key - impressive!!

You're a skilled experienced professionnal kind enough to answer some "non so positive remarks". So good from you. You're a good man. keep on going and be happy and proud of your know how. Respect !

It’s a pleasure to hear you explain all of this, the lathe is really looking nice.

In the UK every day foundries complete thousands of complex cast iron castings using traditional methods. I admire these guys for thier persistence, essentially learning on the job, interesting to see the learning curve and I am sure they will eventually suck seeds. Kind regards Tim

From here in the uk , i salute you guys, very high level of craftsmanship, for all i know you have college education in casting though i doubt it , this is just practical knowledge of the highest level acquired over many years .

Some people just don't understand how much SKILL it takes to do some of these jobs. Skill of the Designer - or engineer, Skill of the Pattern Maker, and Skill of the Foundryman. And - Lady Luck has her place in all of this, too..... And you have to remember that ALL of this stuff is HEAVY. I expect that the sand mold and poured iron probably weigh close to 1/2 ton! And when you have to pull it apart with PRECISION - that takes SKILL, Patience, and KNOWLEDGE. Clarke is PRO.

It's truly amazing the number of things that have to go right to make such a complex casting, and all it takes it one, just one of those things to go wrong and you have made scrap.

Your years of experience came through. I am 76 years old and did some casting way back in middle school. It takes a lot of patience and tenacity to accomplish a good outcome on even small simple castings.

ONLY FOUR TRYS! The man’s a certified genius. Any ‘real’ foundry would be proud to have done a one-off with as few re-dos. 👍❤️

A "real" foundry would have no idea how to produce this item without costing HUGE money for a far less viable product. Congratulations on an excellent not so easy job !

It seems to me like the whole capstan project is being done by all the _right_ people, and we're lucky to be able to see so many different craftsmen and skills at work. That pattern looked like a really tricky part to cast. As it was being made, I kept watching those videos thinking, "I hope the experts can figure out how to cast it because I sure can't see it!" You are exactly right about the number of times it takes to get something one-of-a-kind right. I've never sand-cast anything, but I'm always amazed that the sand sticks together so well with all that stress put on it, especially with such a complex part. Cheers to everyone putting their heart and soul into this!

Oh man, can i feel the tension when you're lifting the core out!

Thank you for your amazing explanation of this incredible process. That casting is a miricle! Also, Dollar is a good boy!

Good on you blokes! There's so much falsity on KZfaq with edited wonder bunny solutions that don't exist in the real world. Thanks for your honesty and for setting things straight. The armchair experts might learn more if they actually did something themselves. Thanks for your work. I've enjoyed watching Tally Ho's return from the beginning. Your casting is a beautiful addition to the soul of that wonderful boat. Well done!

High! On one trip in my lorry to a huge paper mill machinery manufacturer in UK, I was to collect a refurbished roller. When I got there the gate staff told me I would not get loaded because they were having a MELTDOWN? I thought, BLOODY COMPUTERS! They said to go and ask! Anyway as I went to ask about getting loaded, one of the men asked if I was in a hurry or would I like to watch them pour a roller????? then they could load me later. WOW! like you said, hundreds of people there, but I was given some safety gear and watched from a safe? distance? A huge overhead crane with a monster crucible and the heat? it was a spectacle I will never forget. A meltdown indeed but even in a foundry of that size, because I expressed an interest I was welcomed. I don't suppose it would be the same now? I have like many others watched this capstan being Re-born with super admiration, Thanks!!😌😌

Great explanation that clarified a lot for me - and an excellent riposte to all the armchair experts.

can't wait to see a video of the threading attachment on the Hardinge lathe

Like Monty Pythons "Four Yorkshire men" I would say - four pourings- your lucky (look it up). Heartwarming and full of soul.

Thanks for sharing this, Steve, and the explanation. I liked the Space X analogy. People forget just how hard doing complicated things really is.

I'm so frustrated just watching! You all have such professionalism and patience.

Clark is a modern day wizard! So awesome to watch him perform his craft.

I have mixed emotions watching this being made. I did my trade as a pattern maker back in the 70’s and worked in that profession for many years making pattern for everything from large mining dragline buckets and 6 wheel locomotives to small Diesel engine parts. I enjoyed the trip down memory lane.

Please don't let these people troll you and make u change things or talk about them. All you doing is giving them rent space in your head. Forget these people. I for 1 enjoy your videos and the knowledge your sharing!!

Thank you Steve and Clark.

Thanks for sharing men - total respect! You need to understand so many disciplines and shrug off anything less than perfection!

Tell those KZfaq trolls to politely stfu. Until they have spend a day in the foundry they don’t get an opinion. You guys did some hard intricate work with skill and talent that those mouth breathers will never achieve. Kudos, congratulations and it was a pleasure to watch a master at his craft.

That is a tough cast no two ways about it done in a foundry not too dissimilar to the original foundry 100 plus years ago. Nice work guys.

what y'all are doing is becoming a lost art. fine job !

Great video Steve. I'm sure more care was put into make of this part than by someone who has just a basic knowledge of the process in a large foundry. You can't replace experience and knowledge. The old hands on skill is unfortunately a dying art. That's when things were made to last.

Noooooooooooooooo!!! I was so hoping that THIS one would work. I have this weird feeling in my gut right now after hearing Clark saying it didn't work. Damn damn damn! What a heartbreaking process!

You are a real machinist and Clark is a real foundery gut for sure.

The reason the work guys like Clark does is so damn entertaining is not just the outcome (the fantastic product) but most of all the journey to get to the product. That includes the failures, the colorful metaphors, the trail (and error) and most certainly some choice words... The process can (and will) include all sorts of outcomes and emotions which makes it even more interesting. In the end if the project can be finished successfully the rewards are enormous. The keyboard warriors should be ignored... in the scrap bin with these naysayers...

These things are not easy. Well done for keeping the faith.👍

Steve, that was a very nice description of why it is done like Clark does it. I never gave it a thought about the amount of friction there is in sand being used for molding. We used to make patterns out of aluminum for wear and tear from use. They were always polished to remove all of the tool marks for the same reason. Yeah, we had a couple of casting that were a buger to cast which I had to go in and redesign the part to make it easier to cast. I sure miss that old foundry up in San Antonio, Texas, Alamo Iron Works we used to use. It's long gone.

Bob looks good glad to meet Bob.😅

You have the nice video and patience. “They” do not. I’m watching your processes to broaden my understanding. You have a beautiful, many years of experience in quality work with integrity that matches the Tally Ho way which is a rare jewel today. Did we want to see tally Ho built in a billion dollar factory with CAD machines? Carry on my friends.

Wow! What an amazing effort. I just can't comprehend it all. It's so fascinating.

Some great skills total respect and been on the edge of my seat hoping to goodness that something hasn’t gone wrong with the sanding

Thank You so much for sharing this video with us. Awesomeness Extreme! Thanks for being a Firefighter Hero!

I have personally been in many "real" foundries and most people have no clue that most foundries are production foundries that produce widgets not one-offs or small runs. Specialty foundries Like Windy Hill are often more capable of the arisan work than the production foundries. The specialty foundries that I have knowledge of, have had the same headaches as you guys did. I am from Alabama and the specialty foundry that I am most familiar with made the 100 ton Deepwater Horizon 'sealling cap' out of 5 sections, as the castings werw MASSIVE and extremely complex. Non of the 5 sections were without drama and re-tries. When you are not doing production parts, you find out very quickly that there are different rules and that is not to even mention that the 'real' foundries will not even consider one-offs.

fantastic and amazing level of wealth of old school knowledge from a couple of seasoned Master craftsmen's dedicated to their art, getting little sand and dirt on their loving hands

I've followed Leo and the Tally Ho since it's beginning. Leo works smart, but he also work hard. Leo have never hired big corporations to help get the job done. Even when transporting wood across states, someone who happened to be going in that direction volunteer to so the job. He's rebuilt the Tally Ho using hard working people willing to do their best. No different than when the Tally Ho was built. But most important, he has employed local local shops from people working to make a living and not big corporations working to make a killing. Frankly, from an economic point of view, hes done more to suport the economy than many of us do. Local businesses are the back bone of our Economy. Not Jefff Bezo with Amazon, the Walmart family, Bill Gates, Zuckerberg or the likes. People like Windy Hill, hatd working people, some who he has trained ans a shipwright. Good job for Leo and those working for and with him.

I have to say that what is going on here is, to my mind, exactly what NEEDS to go on. Life is not perfect and not everything is a digital triviality. This is a one-off custom piece that requires great care and considerable precision. Critics should shut the heck up and let the master ply his trade....

Steve, your killing us! 🤣

I like you great explaination to the knockers ...read some but not all comments the gang working at the foundry calm and steady at a dangerous job just fantastic

Great job you guys Rock!!!!!

Hi that is a lot of work. But Clark handle it , with his knowledge.

Only four trys to get a good finished piece is damn good. Especially on something as complex as this is on the inside.

Doing a great job, don’t let people get to you. Opinions are like…. Everyone has one.

Clark's wife? is so nice. "It's going to be fine!". Good to have some encouragement in the shop. You guys have been at this for a while, and while fun, I'm sure it's a bit discouraging to have it fail. That's part of why we do it though. We try. We fail. We learn. We try again. Maybe we succeed. Maybe we learn some more. But it will be worth it!

It's funny how nobody realizes how much experience speaks volumes.

Your right Steve, I used to work with a foundry that poured Almag 35 via lost wax and plaster, doing this in cast iron is a way more challenging animal.

Like the guy casting bronze in Pompeii in 79 AD said, "Yep, I'm learning all the time. What doesn't kill me makes me stro- Oh, heck!" 🌋👀

If anyone comments on the number of pours it’s taken, just remember Clark got it in 4 … all those Lilly livered keyboard experts out there, how many goes would it have taken them? that’s the difference, 4 goes to make a prototype is pretty darn good. I. An electronics engineer and when I used to design a printed circuit board, the amount of times I’d forget to add that crucial test point or forget to increase the thickness of that bit of track that just blew because it couldn’t take the surge in current… usually I’d get a reasonable prototype within 4 to 5 goes depending upon the complexity. So guys, it’s not mistakes as such, every new design takes some figuring and we all forget things or fail to remember to modify something before the production run.

I completely agree with you, Clark is a specialist in his field. What these desktop heroes refer to as a so called professional foundry, is nothing more than a production line foundry, they even won't do a one of as this one. Probably back in the days these capstans where also made in a production line foundry. But before such a production line would start up, it's specialists like Clark who also had to find the best and most efficient way to do a cast, once that that is found, the knowledge is there and than it's a constant repeat. (for desktop heroes, copy paste) Don't let those people get under your skin, they're not worth it…

My penny worth opinion, only people that do nothing makes no mistakes.

👍Nicely explained

Got some internet advice for you.... Ignore all internet advice...

Love it when logic is used to shut down the "nattering nabobs of negativism", i.e. the trolls.

Good job guys thanks for the video

I worked in a "real" foundry when I got out of the Army in 1968. We screwed something everyday, that had to be fixed or recast. That's just how a real foundry works.

We enjoy your video’s and the good craftmanship, nice job

your best video--captivating presentation

No need to get upset of that remark. The world is full of their mindless remarks. I cast small in comparison to what Clark and you fellas work with but the results are IDENTICAL in every way. As it is I use and reuse Petrobond. Great stuff but there is another called Delft Clay that is stupid expensive. Anyways, when we fail, not if , we just have to scratch our noggins and start over. Sometimes we have to walk away and get back at it in a bit or tomorrow. we eventually get it right and be proud of the achievement. Well Steve, you sure do keep company with the best of souls indeed. Thanks a BIG bunch for this winning post my friend. A sub to/for you was a great thing to do. EH !

Determination is often fraught with patience and perseverance. All are paths to success.

Bob is as old as me. Hello Bob, glad you are in good hands.

My grandfather was a pattern maker at the American Locomotive Company (ALCO) then went to go on to a career as the same at The GE Works General Electric, now he was driving a Model T to work in Schenectady each day so you know the time period he worked in. He would feel bad for the foundry men because of all the blowouts and issues that were involved in this work. So any of those people giving Clark a difficult time out there you don’t have the slightest clue of the Trades involved here. What is so sad is we have hardly anything left of this skill or trades anymore, it’s all going to India. We can barely make a gun barrel for a Howitzer any longer. Sad

Great explanation!

Cool lathe. And anyone who does casting has Job looking fidgety. Thanks for showing us how.

Well one thing is for sure. You can't say Clark isn't a dedicated man.

Tkzz for sharing,..,.peace

I spent years on the machining side of a company with a professional foundry, I have witnessed many blowouts in metal flask, have sent castings to weld after cutting into sand pockets or porosity, some castings are scrapped at cleaning some from x-ray, it just happens. If you aren't running a continues production part making hundreds or thousands of the same casting you are going to have issues from time to time.

Good for you. Bob is a great name!🤔

My feeling is don’t share the first 3 trial runs, because that’s what they are; simply trial runs, to get to the final successful pour, I’d rather see the final run and only mention all the work that went into getting to the final successful pour. Great job guys!! I love following along with you! ❤

Thanks for all the detailed information on this complex operation!

Haha, the professional foundry comment I am also confused as to what that means? If they are just talking about a bigger foundry then they would most likely decline the job as they know it will take a few times and isn't worth the time for a single part or the cost would make it unfeasible. I facilitated a run of 12 ductile parts and was turned down by a few foundries. When I found a foundry that was willing to pour ductile in a small run it took 4 tries to figure out how to pour it and then we had a 30% success rate. This was a very professional foundry with many many years of experience they told me every casting has a sweet spot for venting, gating, and what direction it will pour best and the experience gets it down to 4 tries instead of 10. Casting is better suited for when you need 100's or 1000's of parts we could have redesigned the pattern and part for better success but for 12 parts we just pushed through. With that said Windy Hill Foundry is as experienced and professional as it gets for small-run casting that seems to be their specialty.

There is a lot to be said about patterns that Clark gets and what he has to go through just to get a casting. The typical scrap rate for a foundry is 3%. I agree with the fact that the flask should have been built differently. Provide for clamping the mold together rather than just relying on weight alone. In my opinion, the pattern has issues, too. A redesign could have made the process easier. Having watched the pattern construction, I don't think there was much communication between the patternshop and Windy Hill Foundry's capabilities. Trusting a patternshop to give you exactly what the foundry needs is like trusting that a draftsman put everything on the drawing so you can make the pattern.

You just gotta learn to ignore the haters and the arm chair quarterbacks. (Ignoring my own advice....) Arm Chair Quarterbacks, internet experts and haters: I've been around machining my entire life, these guys are EXACTLY who you want doing this kind of work. Of all of the living people on the planet who have ever been capable of this kind of work, and this kind of quality... 98% are in nursing homes. This is essentially a dead art. Casting is one thing, large complicated ONE OFF castings that aren't just decorative, are a whole other thing. Could a billion dollar foundary do this better? Sure. But they'd spend a half million getting the process right, dialing it in to absolute perfection... and then they'd only have 1 customer looking to buy just 1 part, ever. I work for a company that builds the equipment that machines the engine castings, transmission, differential castings etc. You have no idea how much time and money it takes to get those engines right, and how tightly they control the tolerances. If you asked someone to build you just one from scratch.... my god the money it would take to do it the way they the OEM's do. But there are guys out there building their own from scratch. Do their shops look like the Ford, GM or Stellantis production lines? No. They are garages and old warehouses with old machines, old men, and bits of this and bits of that scattered here and there. Get off their balls, they are the among the very last of an exceptionally talented and tragically endangered breed.

Thanks for the videos. It is a great project. By the way Bob's maiden name is still up on the overhead guard. LOL.