Steam Stoker Engine Restoration Part 14: Molding & Pouring Cast Iron at Windy Hill Foundry 

that was an awesome visit to the foundry. could hardly believe it when he reached over that furnace and snatched the crucible out. the man must be fireproof.

Great to see two nice experts meeting at a common project.

Clark is the most highly skilled ...humblest man alive! What a pleasure to watch a craftsman..better yet, TWO!

Hi Keith, this is so nice to watch the progress of this engine. I did some cope and drag casting at school, some 50 plus years ago and this takes me right back there. You guys certainly have some space and equipment but more importantly the enthusiasm and drive to get a project through. Well done, fascinating work, looking forward to the next installment.

My Grandfather was a Fireman and an Engineer on the NC&StL and later the L&N. I have a picture of him hanging on my wall standing in the cab door of NC&StL #559.

Thanks Keith for the great visit to the Windy Hill Foundry. I'm a 73 year old hobby machinist that started his work career as a casting designer in CT. Watching the episode brought back many memories. To this day, the unique smells of the foundry are fresh in my mind. Spending time in the pattern shop was a favorite. It was there I first laid my hands on a Bridgeport mill; I now own one. The pattern makers were the true craftsmen, working with mahogany and lacquer (more memory connected smells); no 3D printing then. The The operation had three ferrous foundries, Grey Iron, Malleable Iron and Steel with a history that started in the early 1800's. When driven out of business because of government EPA over reach (along with many other US iron foundries), production went to China, and then ceased altogether.

That looks like a mean way to make a living, buddy you earn your money no doubt, great job

Just binge-watched the series last night. A couple of things. First, I think i would have employed the 3 drill method of removing a broken piece because this location only retains a cover, and does not appear to be structural. This method uses a small 1/16 drill at the edges of the broken piece, just inside or slightly into the threads. Care must be taken not to wander into the softer cast iron. A larger drill, bridging the two smaller holes cuts out the center of the offending piece, leaving the outsides of the stuck piece unsupported. A newly sharpened cape chisel or sharp center punch is then used to knock the sides in freeing the threads and the pieces. any small intrusions into the base threads is inconsequential in this application. Second, I would have modified an Armstrong rivet buster chisel to create a tool to engage the steam ports in the valve sleeves from the gland end and drive the sleeve out from that end with either the press or a hammer. Cooling the sleeve with liquid nitrogen would probably help, and it is much more available than one might imagine. Just remember that there is an asphyxiation hazard that is easily avoidable, but nonetheless serious. Lastly, the gland packing appears to be graphite-asbestos, very suitable for steam. I do not know what is presently employed, as asbestos is an issue in itself, but several years ago I obtained a number of spools of old-stock packing from an industrial power-house in a number of sizes. I would be happy to contribute to this project by donating suitable product to repack your glands, if the sized are suitable. Let me know. Were I to be in need of piston rings, I would contact Hastings Mfg on an off-chance you could get modifiable products, or semi-finished stock. Just a thought. Also, cylinder sleeves are widely available through the automotive repair industry, but I don't have a source myself.

Every large factory in America had a foundry. I worked in one as part of my apprenticeship for United Shoe Manufacturing Corporation in Beverly Massachusetts

“We’re all always learning” - right on guys! That is certainly the right attitude in this type of work.

Did I just watch two grown men play in a sand box ??? ... I think I'm jealous.

Brings back memories of Jr High metal shop class, making molds and casting aluminum. The teacher did the pour, but we were able to observe the pour.

never knew how that was done ..nice learning video !!!!! thank for no ads , youtube has gone crazy with ads lately !!!!!!!

I'm looking forward to seeing the machining of them.

If you have ever "hand bombed" a large locomotive you'll know that power stoker is solid gold. Nice job everybody.

Windy Hill is the best foundry 😀😀

The riddle of steel!

I was lucky enough to learn about foundry and pattern making back in high school. It is amazing that the way it is done is the same as back in good old days.

Fascinating, thanks for bringing us along

Thanks Keith and it's always good to see....Clark do his stuff....!

"We are always leaning." I am retired from a long career of scientific medical research. Then I taught high-school, and then college; four years each. Every class, every week, I learned something from my students. They were f5 years younger than me, but they lived their lives, and had learned something I had not learned, until I taught them.

We used to paint patterns. Black for prints Yellow machined surfaces Red would be left as cast Gave the moulders advice on where to take care

They turned out well!

That was really cool to watch.

Nice job on the Pistons, Clarke does a fantastic job.

Terrific watching that process. Can't wait to see you machine them. Also, I'd like to see how you make the piston rings.

I found Windy Hill Foundry watching your channel Keith, I enjoy his work as well as yours.

Wow, really enjoyed this episode! A man truly does not know what a man does not know. Clark is truly an artisan. So much of what he does is about “feel” rather than certainty. Thank you Mr. Rucker!

That was fun to watch, nice work .

The patience and persistence pay off! You honor the people that designed those machines. :-D LOVE the Windy Hill collab videos!

Suggestion for Clark: throw a simple overhand knot in the cord for that hoist. Knotting the connectors together is just about as good as using a locking connector.

I'm happy to say I knew right where this was from the first frame. It kind a threw me, but it's a great thing that these guys work together and share their knowledge with the masses

Love that Pedernales Electric hat........God Bless Texas!!! Nice video Keith

Wow, that was a really cool process. Reminds me of the melting pots at the steel mill, just a little smaller 😊. That's gotta be a pretty heavy crucible when you consider how many pours he's doing in one go. Carrying 50lbs of molten iron, respect 👊😁

Takes me back to the early 70's when I started work at Clark Bros here in Olean. I took a call back after lay off to the Chipping Floor. During the year I spent there,, I was often sent out to the foundry for a big pour.

THANK YOU...for sharing. Watched and very much enjoyed.

Fascinating process... slow is smooth, smooth is fast. These processes put a premium on that maxim. You can try to automate/ mechanize some steps, but here we see that these processes are so simple as to defy automation. People will talk about 3D metal printing and EDM, and yes, you can do that... but ten 3D printers probably couldn't keep up with a single foundry line as far as a production run goes.

Great collaboration. Really enjoy the iron foundry work Windyhill does as well as your finish machining.

Fantastic video, that was great to watch!

Another fantastic update. Thanks, Keith!! #StripeHype

Hello Keith: Kudos on your many enjoyable, informative, really fascinating videos. You are truly a master presenter. Thanks for putting in the time and energy to let us look over your shoulder as you go about your work.

Great video! Masks would be a pain for collaboration video, but with voice over it would work and keep you two safer.

Thanks Much Keith I really enjoyed that episode :) Thanks for what you do!i

A lot of work for a small part, just 2 of the many needed to produce an engine. Just imagine the total work involved for a complete engine even before any machining, I take my hat off to the foundry workers of the past, almost everything by hand.

All so really cool!!

Way cool...thanks for sharing.

That was great to be allowed to view. It's an amazing process.

That's going to be a great video when it comes time to do the machining. I really enjoyed the casting work!!!

Thoroughly enjoyed this video and all 14 so far. Learning alot. Keep them coming Keith

Hi Keith, I been watching your videos with pleasure for some time. Your manner is so relaxing that your videos are a joy to watch. You are an expert machinist and presenter. I'm learning a lot. Never stop. Carl

Toured the Powermatic in McMinnville, TN about 1973 to see their manufacturing process. Their casting process was much the the same except for some automation. This video brought back old memories. Really enjoye this.

One of the best step by step casting video I've seen 👍

Thanks!

Interesting video, thanks for sharing it Keith.

Wow nice plus got too see my favorite you tubers in one video!! Clarke always does a great job!!thanks guys!

To keep power cords from coming apart I will sometimes tie a knot using the two cords. Very interesting casting video, thanks for making it. Looking forward to seeing these castings being machined. Stay healthy.

WELL Done! "CAINT" wait for the next episode on this awesome endeavor.

Excellent video! It is great to see this element of your project and visit the foundry where the casting was done. Well done ✔!

Very, very cool to save those old engines!!! Good work men!

I learn so much from these videos !!

Great video Keith, I've got some old machinery 4-sale modal A monarch lathe lot 74 no3,camel back drill press, shaper and gear cutter.

Keith, Really enjoyed watching and learning more about foundry so of the process’s, thanks for sharing your video looking forward to seeing your next videos on this project and other videos of other projects in the future .!.!.!.

I've got one of those straightedges Clark. You do very nice work!! I love these kinds of "living history" videos.

Wow, very instructive and truly cool to watch. Thanks. Appreciated.

OPSL- Older person, Still Learning

Great video, as I was watching you pack the sand into the mold box, I caught a glimpse of a cattle brand and the letter P on you belt. I continued to watch and was wondering what year you went to Philmont Scout ranch. I went there in '72 and wore out my first belt and found someone to get me another one. Keep up the great work.

Most excellent! Thank you for posting a great video

Very interesting process.

What skills!

You can get old and old, there is anything, which is new and can be learned.

Thank you Keith ! You always expand my knowledge horizon!

Fascinating, thanks for sharing this video of this lost art...

Thanks for bringing us along.

Beautiful. They had only a certain level of technology back then just like we do now. Stuff in 100 years (hopefully) will make what we do look primitive!

Great segment, that pour was intense !!

See you lads having a bit of trouble with 3 D printed patterns , I use them but spend a lot of time smoothing the surface as the print layers although they look smooth can actually be quite rough and cause the damage as the patterns are lifted from the moulds , usually finish them off with a few coats of primer from a rattle can . Regards Robert Partsmade 🇬🇧

A cool project. The pour looked a little scary!

Really love the collaborative work, great stuff Keith!

Thanks. Very interesting.

Very interesting

#D most be a great tool for making very detailed patterns and a nightmare for the foundry who has to get the pattern into the sand and make it work.

Good informative and interesting video Keith, thanks. I look forward to the machining.

There are many dark arts in the foundry and measuring the raw volume required and getting it right is one if the darkest. Great video keith

I’m ready to see those get turned. Seems like with one off castings, you always need to pour a spare...

A very informative video, looking forward to the machining.

Great job, I did casting back in high school a lot of fun. Many years ago I'm starting to cast aluminum again can't wait to get back into it before I can't, if you know what I mean!!😁😁😁

Amazing....... Guess there is a science and method to everything.

Keith, An enjoyably video... Cheers Paul,,

Great learning video. Thanks!

Was glad to see the rapping tool being used. Clark is a little hesitant in using it I guess.

Missed a joke there Clarke. KEITH: "Say hello Clarke." CLARKE: "Hello Clarke." 😁

We did the same video. Black for printing Yellow machined surface Red will be retained Provide mold customers with advice on how to care

I believe if I was doing this I would have made three or four molds considering the cool off time & keep to two best & remelt the others as a do overs. Would have only cost you the time at the sand box. I also see me useing a air hammer & a press to make the molds.

It'll be interesting to see how you make the piston rings your side of the puddle.

Interesting video thanks for sharing.

Hiya Keith

There would have been the possibility to turn the original pistons down a bit on the OD and add a shrink fitted ring to it, with the right OD for the re-machined bore. This was common in the refurbishing practise.

If you know the volume of the part there is a way to get a pretty good estimate of the amount you need, though that is dependant on the size of your riser, gate, and the like as the risers weight helps push the metal into the spaces

Need bigger pistons because we need more power!! 😎

For more boundary molding technique, see the RU-vid videos old foundry boy.