Carvel Planking Ep18: Bronze Castings, Patterns to Polishing 

Love your work Ian - I’m an amateur boatbuilder and carpenter by trade and love your videos👍 wish you did two a week!

Lovely work Ian, here's a tip you probably know but wasn't shown on video. When grinding soft metals using sanding discs or belts, dress the sandpaper disc/belt with beeswax. It keeps the grit from loading up with material and extends usefulness of disc/belt. I'd worked a number of years before an old salt of a maintenance mechanic showed that trick to me, so I'm passing it on for free. I'm sure someone will find it useful. Those parts look amazing by the way and that cutter is coming along beautifully. Cheers mate!

‘Really glad that I’ve found these vid’s Ian (linked from Mike’s "Classic Boat Supplies” web site) and particularly happy to have found them right now. I’m roughly at the same stage as yourself construction wise with a rebuild of a strip planked Huon Pine H28, after being stripped right back to a bare hull and deck frames only. I've just fitted the cabin sides and cabin top framing and am looking at what patterns I need to make for some bronze work (replacement rudder gudgeon, external chain plates, porthole external mounting plates... I’m looking forward to seeing your future episodes.

Brilliant job Ian. Proving your a Master Boat Builder once again. The idea on patterns came in handy for me, as you know I'm building a similar traditional boat..

Most enjoyable and enlightening, Smithy. Look forward to each episode.

7/20/22..Hello from New Orleans area USA 🇺🇸 ! Much enjoyed my coffee this am watching/listening to your video on 'Trmplate making for Bronze casting'. Very articulate in your-very experienced-sail boat hardware fabrication procedures. Great camera lighting & close-up shots. Beautiful results, Shiney & smoothe hardware, after lots of time (&$$) has been spent. Will follow along & see you again! Stay safe in your all yur grinding/polishing..then pause & have a 🍺🍺!🛠⚙👍👍👍🙂

Great video Ian, as always, I'd never known what went into bronze castings till I saw the process on Tally Ho when they made the floors, you made some fairly complicated pieces here, great work! When I see old cast iron pieces I think of the pattern makers that made them in wood first. All the best from Scotland, David.

Wonderful wonderful! Thank you for this excellent video

Great information. Thank you.

Thanks great stuff also I bought your book on boat building.

I enjoyed watching. The wave of the future these days is in powdered metal sintering process. Really the first new metal casting process in generations. You probably know it, but for readers, its powdered metal, (bronze, stainless, steel of different alloys etc) pressed into a metal form or even a strong fiberglass form which when ejected then makes a metal part same as the original but unconsolidated like parts of a damp sand castle. Literally seconds between one part formed, ejected, and the next part formed. These unconsolidated parts then are sintered in an oven to fusing temperature pretty much like fired ceramic. They emerge virtually as good as the normal traditionally cast part, ready for machining. A good video overview is here: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-PetwxkqM-kQ.html I just wish that more marine castings were mass produced to bring the prices down. I almost suspect people could learn powdered metal casting ramming powder by hand in a garage but it requires a sintering furnace as opposed to a crucible furnace. That fuel filler cap was superb! The bronze mast caps are a beautiful unknown tradition to me.

Thanks.