Finally!! Someone actually using high school math in real life. You are my hero!

Why is this the _first_ foundry video that actually names and explains the names and uses of the forms that hold the mold for a part to be cast? Wonderfully done. Thank you.

Thank you for documenting this on video. It's fantastic to see all the different trades that go into rebuilding a boat like that, all the skills and craftmanship that it requires. Thank for you for sharing this with us

What a fantastic collaboration this is; bringing together superbly skilled craftsmen such as yourself Clarke, Keith Rucker from Vintage Machinery and Dave Clark -The Pattern Guy, to recreate the capstan for Leo Sampson's stunningly beautiful total restoration of the famous British naval architect, Albert Strange's 1910 Gaff Cutter, Tally-Ho. Those of you whom have yet to discover these truly inspiring individual's skills are missing an absolute treat. Thank you Clarke, for your critical part in this amazing restoration and for posting such interesting and educational content. Your videos just get better and better, I never want them to end.

This whole project of Tally Ho has turned into something so amazing that this sailing yacht, which it is, will be far and again so much more famous than she ever was in her previous life at sea!!! Very nice job by all that have worked so hard to make Leo's dream come true, not far to go.

Memories of my first apprenticeship working at a foundry in Scotland springs to mind while watching this cracking video,that was 50+ years back

It's great to see a collaboration of so many KZfaqr's. Tally Ho is a great project. Thank you for being a part of it. Have a great day and stay safe.🙂🙂

Thank you for your help with the Tally Ho. It's so interesting to see how the casting process works.

I'm tickled to see this project come up! Been following Tally Ho and Dave Clark for years. What a fantastic collaboration. Windy Hill's name will travel the oceans! WTG Keith.

I've been watching Tally Ho for a couple of years now... and I'm so glad for these collaborations - but more so because some of you collaborators are willing to video your part of the project and share it with us. Thanks for all the hard work you put into this - and especially I thank you for sharing it with us.

What a great video explaining the process for making the core boxes for the mould. Each time you said "that will work" while making the components gave me a smile because true craftsman know what is needed to get the job done and not fret over details that don't add value to the product. I am looking forward to the next video for sure! Thanks for sharing!

I have watched Tally Ho from the beginning and every outside skill that has been needed has been clearly explained so thanks for keeping up the standards. Look forward to the next couple of videos. Good luck.

One tooth out of the Tally Ho gear, without it, it won't run… Great craftsmanship, keep it alive, great job, love every inch of it…

Great to see the behind the scenes work to cast such a large piece. Hats off to the Windy Hill Foundry. The plasma and laser cutter are sweet!

Awesome. Nice to this coming round. Great collaboration by 3 great artisans. I guess this is why Keith needs his Monarch 612 up and running.

I pour silver so I know the procedure very well. When I was just starting my mentor/teacher asked me to get him a flask so I did. He started to laugh and asked me to get a bottle of rum to fill it. Of course now you know why he was laughing. I still chuckle every time I reach for a 3 x 4 in flask to do what call a closed pour. That core is a beautiful piece. A shame to cover it up in sand. Your friend Is lovely and has the nicest, most natural smile. What a great piece for cutting parts in that laser. I think I am in love, LOL. I am currently waiting for Leo to figure out the core for 2 medallions I have offered to pour in pure silver for Tally Ho. They can be as heavy as 10 ozt. The placement is still a ? and the design has yet to be 3D printed so I am patiently waiting for Leo to find the time and place for them. They are gifts for this wonderful build he has taken on. Thanks a bunch for having us along making this flask and core. I know how important these pieces are for the casting to be just perfect. There are few in the world with the mix of your trades. If you have a few minutes stop by and pay me a visit I would be honored. Glad I sub'd you so I get notice when you have posted. I picked up a couple things for building a large flask like this. Take care eh !

Enjoying the content. Been following the Tally Ho project for years now.

Masterclass. Thank you. Your comfort with complex geometry is impressive!

Thank you for declassifying the drawing. The sketch was very informative.

Delightful! It is a joy to watch a you build.

This tells me about things I knew nothing about. Good explanations.

Nice looking flask, with nice wood from my country, Sweden👍

Good work mate,thanks for sharing, Lord bless you and the USA.

Thank you for trying to keep craftsmanship alive!

A great watch 👍🏻👍🏻 I'm sure Leo will be very happy.

I have been looking forward to this series. Thanks for posting.

Unbelievable amount of planning/calculating/fabricating is involved in just making the core box. Fingers crossed it will deliver a perfect casting on the first try.

Amazing skills, excellent video.

I am so impressed. You actually explain things in terms that make complete sense. I'm an industrial mechanic of 37 years and you explain things so well that I understand. And that's not the best thing. You're doing it for Leo. Incredible. Thank you for sharing so much. Deeply appreciated.

14:20 when you are cutting the steel to bend it and weld it again, I find it easier to cut the slot in the middle and leave both ends connected. Makes it super easy to get a good bend.

I love KZfaq just for the reason it has aloud me to find you guys. Many years back i started to follow Abomb79. from his channel I got a glimpse of Kieth's channel. During the pandemic I discovered Samson Boat Company and watched them Independently of anything else going on. It's funny how paths will cross. I'm a person who believes the way things used to be done should be remembered, I can't wait till you pass off your castings to Keith so he can do his thing. To be honest what you guys do and what Kieth, Abomb79 and Leo are doing is love, Love of an art, love of an discipline, love of a skill, Love of a trade. I fear the lost of trades jobs. At the end of the day don't for get the pattern guy.

My grandfather was a pattern maker. Really cool to see how this video!

very comprehensive - a wealth of detail mates*

Does anyone else remember what it felt like when a drill press grabbed your glove and wrapped your hand up on the chuck? I still cringe every time I see someone wearing gloves around a drill. Keep up the good content!

The is just on another level good stuff!!

Awesome and a lot of work into this project. Good to see all this collaboration.

I have watched Tally Ho from the start .On there boat rebuild.. Happy to see they have a expert repairing there part .

Great Video. Thanks guys

I did some casting work a long time ago. In addition I taught mfg processes for our apprentices and we visited iron, steel, and alum casting facilities. You did an excellent job explaining the flask and parts. Looking forward to the next. I saw V8, V12, and V16 blocks cast at our Mapleton, IL foundry. The 3600 series engines produced 400 hp/cyl.

You're a genius, Clarke !

Great explanation of the fine work that you do!

Wonderful , clear description of the process. Thanks.

Glad to see it coming together.

Swedish pine! 🌲 Nice video! 👍

looking forward to part 2!

Thanks for sharing this with the world! 🇨🇦

Great video. Octo-excited for part 2!

2 part, 3 part, 4 part, it's all good.

so much more goes into this than one would guess. can’t wait to see the upcoming work.

Loving the behind the scene type video. Looking forward to part 2.

OK, just how many makers that I watch, are going to show up on Leo's capstan? Keith, Windy hill, Gypsy, anyone else? Adam Booth? GReg Cohen? (If you like good candy, Lofty Pursuits is the answer.) Forgot one. David Engel, from Engel's Coach Shop. You need a copy of the 20 mule team wagon train, David has done it. Wheels were over 1000 pounds, and there were 6 of them. Wagons were WAY over that much! steve

Can't wait for the next video!

Greetings from Germany. Making things beats shifting paper from one side of the desk to another.

Tkzz for sharing .,.,peace

I'm in Hattiesburg pretty much every week. Are y'all from Mississippi? I haven't heard of another city called that, so I'm figuring that you're near here. I'm glad to see local people getting their content out there and glad y'all are helping with Tally Ho.

Great work you are doing! Thanks for sharing.

Lots of work!!

Really interesting. Thanks for sharing your work.

This project is fascinating, thank you for sharing your cleverness.

Thanks for your hard work. Looks like a fun project. I can't wait to see the pour.

I am very impressed with your craftsmanship. This requires a dose of common sense combined with experience and improvisation to realize such a project. Chapeaux. Also nice to use modern technology - laser cutting of wooden parts. Your way of working, care and no-nonsense approach fits in completely with the Tallyho renovation approach Best regards from the Auvergne France

for the safety experts who always comment, By my count he had 5 digits on each hand that appeared to be of full length and intact, anyone who's operated a benchtop drill press like he's using knows that you can grab the chuck by hand and stop it so having that glove on is not a problem.

Thanks Clark and hope you got a strong back on this deal...

I would also add some steel strapping to the molds just to guarantee they can't expand at all. With things like that mold, it is always safest to overbuild them. Since you only want to have to pour it once. Plus, you will be keeping the mold for future use.

Dave did an amazing job on that pattern. As others have said, what a great collab. By chance is this going back to Keith to be machined, or is it going to Leo and he has somebody there doing the work? Given that Keith just finished rebuilding his big lathe, I want to say it is going to him for the machining work. Going to be great to see!!

Appreciate your process to help us learn

Like You, Ive been a tradesman all my life... few years back another long time tradesman in a nieghbouring shop was wearing gloves while using a drill press such as You were @ 18:00... let's just say Stubby ain't in the trades no more.

If these dudes knew my age they'd hurry this project up a bit.

Coming along Clarke. Lots of work there.

Love the content! I heard you mention Hattisburg...turns out we're nearly neighbors--I live near the Rez. Keep up the good work, can't wait to see it on Tally Ho

Awesome job, man! Well done !

I just saw the other day an India forging video where they used 1" flat bar welded in a standing grid on the bottom of cope and top of the drag made of just sheet metal. In order to hold the sand much tighter. So tight they were dropping and banging them arround that none of the sand never fell out or apart. Plus the alinements were made of flat bar bases with pipes and pins welded to those. This also stiffen two of the sides.🤔🤔A much lighter cope and drag 4 sure. Some were even 3' x 3' x 6"

Been waiting for this video for A YEAR!!!!😅

Amazed skills. Thanks for explaining!

nice work. It really will be a nice finish to Leo's masterpiece.

Towards the beginning of the video Clark shows an example of a steel flask, and yes they are heavy but extremely durable. I'm pretty sure that particular one was manufactured by the "Whirl Air Flow" cooperation in Minneapolis MN. They are still in business today manufacturing pneumatic transporters but no longer make the steel foundry flasks. Shanafelt Manufacturing Co in Canton Ohio still makes steel flasks however theirs are made of corrugated steel plate whereas Whirlair flasks were made from a proprietary hot rolled section with one rib in the middle on the outside and two short flanges on the inside. Both manufacturers formed the corners and welded both halves together underneath the guide mounts. McEnglevan/MIFCO (speedy melt) Offered aluminum flasks of similar construction (roll formed or extruded section, bent corners, and welded) and had cast guide lugs welded on. I'm not sure who actually manufactured them for McEnglevan but unfortunately they don't appear to be available anymore.

Great video this is always such an interesting process.

Awesome job

Good Job Clark

Nice work as usual!

I feel like the old foundries just said, "hey, we'll shape it to the right size if we have to grind it with children teeth, and we will!"

Not just a master class on casting, but also a master class on how to make an informative, well-shot and crisply edited KZfaq feature.

Even though I intellectually KNOW it is a video I instinctually look away whenever I see welding. When I worked in a machine shop, way back in my youth, our equipment still had little plaques riveted on reading "Approved for the war effort" while Japan had been completely retooled with fancy new equipment.

I just love the way you tell a story. "Excuse the construction that is going to take 10 years" was absolutely hilarious quip. I also liked how you showed the different types of tools and why they don't work

You mentioned not being able to find your soapstone. My wife used the old chips from bars of soap to mark fabric and I've wondered whether it would also work on metal. Of course, lots of people are using liquid soap now.

The amount of skill and expertise going into this project from everyone involved is astonishing.

interesting video thanks .i follow Leo and the boat

8:26 Ahh Laura she is sooooo lovely, what a lovely smile x

This is gonna be awesome

Amazing!!!😊

@1:10 when I was in foundry I can remember if our terminology was different but the order we payed the two halfs up was backwards. We always started with the pin side because the pattern boards always located off the pins. And it's really hard to locate a split pattern on the hole side of the flask.

Clarke, that's not such a pretty sight on the wall behind the drill press. Might I suggest an industrial twist lock type socket and cord ends and maybe having only one device plugged in at a time.

Nice Thanks for this video

Nice!

this so new to me ie casting loveing it only thing i can comet on is if you cleanned the mil skale off befor plasma cutting you get a nicer edge .... but dont think it mattters in this aplication lol

I have been looking forward to see you pour this. Its amazing the work and dedication you put in to this. Give Dollar a belly rub for me and keep up your great work!

Hurray ! Go WHF Go!

Very enjoyable video, thanks for making it (and of course, doing the work). I do have a question for you though, you had quite a bit of setup to get ready for this pour. Have you thought about casting additional pieces? Seems like there has got to be somebody else out in the world who would want a magnificent capstain for their antique yacht.

oh man, you got scooped by the news

Good wood