Windy Hill Foundry as they pour the casting for the Tally Ho. Second pour Unabridged Version 

I’ve been watching TallyHo from almost the beginning. Y’all are doing a great job. It is very interesting. And I really never thought about it. But it is great to know we still have craftsman in this country that are able and love to do these things.

The amount of patience is remarkable.

Hi Steve, pay no attention to the Tik-Tok twits there are plenty of us oldies out here who ate extremely interested in all the minutia involved in this creative progress. As someone who has been watching Windy Hill Foundry, Kieth Rucker, Dave the Pattern guy and Leo and the Tally Ho rebuild I am fascinated by the demonstrations of the skill of all participants. Ignore the impatient idiots and carry on making things your way. Thank-you for the time and effort you put in to this Video.

Clark, I was on a US Navy sub tender in 80s, we had a huge foundry in the bottom of the ship, in my spare time I hung out there, they were still using techniques from the 40s because they were proven to work, you're doing a great job, that's hard to do.

I think the best part of watching both you and Clark working through these process’s is your attention to learning through the process. Every failure creates a learning potential. Clark obviously goes through a litany of thought based on passed experience, which is vast..

I've been watching Tally Ho since Leos 1st video. To see craftsmen working on the capstan rebuild including the trials and tribulations of formwork is a sight to behold. It shows just how much workmanship went into the original build over a 100 years ago! Modern day engineering and manufacturing doesn't give credit to the processes involved to churn out complicated shapes such as the simple capstan on Tally Ho! I always marvel at the feats of engineering involved to make these old, but very functional items. Well done guys, I doff my cap to you for your persistence and craftsmanship.

Anybody that thinks Clark is out of his league has no idea what they’re talking about. I don’t think a modern foundry would touch this job. This is true craftsmanship almost lost art so whoever wants to talk smack about Clark needs to think about it next time before they start typing.

I appreciate these videos very much sir, nice to see what really goes in to making a mold like this.

Thank You for sharing this with us. Very appreciated.

A carpenter adjusts a workpeace bit by bit. A bronze cast just requires a few attempts. Craftsmen at work can be recognized. And craftsmen you are all! This is just what it takes. There is a foundry in my vicinity. I know that these guys are hardly ever "getting there" at first pour. Patience does the trick! Overall, I love this video. It shows that pouring metal is a craft unlike and still like any other. This video, in the context of all the others, is G O L D !

I really like how you show that each prototype pour is a learning process which has be to iteratively improved by the lessons learned from the previous failure.

Great comments on what was happening during the pour and making the 3rd pour. This mold definitely takes a LOT of preparation and care to get a pourable sand casting shell. Steve, Thanks for sharing!

Anyone who doesn’t get why the floor is sand has never dropped molten metal on concrete 😮

Increíble artisans, people who comment who have never been to an industrial or artesanal foundry are truely commenting out of turn. The work that windy hill foundry, Clark and his team, are carrying out is second to none. This is sadly a dying art form, from AOB it’s sad to not see a younger generation assisting and learning from true masters of their craft. The finished product will be incredible (Clark will never give up, something the younger generations should learn) and will form an integral part of a unique project that is Tally Ho. Keep at it Clark et all…. And looking forward to seeing the final successful pour!

You guys are great and these videos show the kind of skill and resilience needs to make these one-off parts. I am in awe of their talent to make this happen. GREAT WORK ALL YOU GUYS!

There are a lot of things. I would like to say about how awesome this work is... I guess what I will focus on is how well you guys understood what it means to "help" as opposed to influence a project. I am sure that is why Clark likes having your support so much. Really awesome patience, tenacity and craftsmanship was exhibited in this project. It is very much in keeping with the Tally Ho experience. Thanks for filling in all the details that Clark edited out of his video. Now this is real drama with impact!

The patience and perseverance of you guys is amazing. Keep going!

A lot of people forget that foundry work really is an Art, a highly variable craft more than a perfect science. The molds are impacted by the environment they are made in, sand recipes get adjusted based on changes with supplier, the current temperature and weather, the size of the piece being poured & how the mold is composed. There are general recipes to get you in the ball park but particle size, overall consistency and even the very composition of those particles(silica/quartz, etc) will mean 2 people both starting with equal amounts sand and water and binder may be actually looking at 2 very different things. I wouldn’t be surprised if the quality of the water had a noticeable impact and it’s up to the Foundry Master/ Site Boss to make these adjustments. Even after the molds are made each one will have its own unique considerations made for where vent holes and/or risers go, if a catch basin for initial turbulence is needed or other special considerations will be used to feed the casting, the overall size/draft of the pour spout and those feed gates. With so many variables it’s has to be expected that things won’t always go right the first time. Every new pour is unique and another notch under the belt toward becoming a master of the craft.

100% cool that you told us about the "blurs"! Thank you!

Love all the work and thanks for filming it!!

An excellent example of patient perseverance

I'm starting to think I'm not going to live long enough to see this work. This is a big job and the process the original parts were made is becoming a lost art.

Thanks for supporting Tally Ho!! I am subscribing to your channel because you support Leo!

Good day to you all. Steve, , , I sure don't spend as much time as I would like visiting with you. As when I am casting pure silverI run across most of the difficulties the fellas at Windy Hill do but at a far smaller scale and just a 2 piece flask/casting. Grams instead of pounds but the problems that pop up are identical in every way. What really makes me chuckle is our process while working in a dirty, cobbled looking setups produce such beautiful pieces from within them. Sand, dirt, oil's, scary high heat create the things we need to make our world more enjoyable or liveable. When the flask had that blow out your hearts must have done the same. All that work now needing a newer approach to the pour are still hanging in there. Many times I have had to walk away from a fail to return with a new gusto for that perfect result.Well folks, All I can say is ONWARD, Yer all doing great ! ! !

You have an amazingly well trimmed beard, sir. You remind me of my first industrial tech teacher, God rest his soul.

Great video Steve and thanks so much for your help👍

Love your video’s!! No rush, well explained. And honoust… not leaving faillure out!

Apprenticed as a sandbox moulder on a sand floor using cores, nearly 60 years past, basic process will never change. They work simple

WOW....JUST WOW. What frustration. You guys have more get up and try than I could.

Thank you from for the most instructive and interesting videos. I have learned a lot about the skills and pitfalls of foundry work Your perseverance is almost heroic! As we would say in Australia, 'don't let the bastard beat you.'

Total respect to you guys… you have the patience of angels… I think I would have turned the air a deep shade of ultra violet !!!! 😊

Hell of a job!

i remember doing some casting way back when i was in school, so long ago i forget what it was i made, only casting in aluminium - but i have a smile on my face watching this, i bet the old boys who made these originally are upstairs looking down on you with a big grin - 'we used to make a dozen a day' its a hell of a skill with much patients, i'd be tearing my hair out - great video and thanks for sharing

Wow just Wow. From Australia with all best wishes. My message to Gen X , please watch this and understand perfection comes with patience, NOT Tic Toc. So enjoyable. Thank you. Cheers.

Clark, for someone who has no idea how to do this, you're doing great. Keep going. I couldn't begin to do do the work you do. I appreciate the failures too, most of my work ends in failures, so it's good to see real people experience real issues.

THANK YOU for explaining the pixelated bits. You read my mind; it WAS drivin’ me nuts. And thank you all for the care. Wise choice.

Admire the craft, dedication, persistence and camaraderie that goes into that Tally Ho Capstan, I guess just than one piece of the whole boat is half the cost of the project, but its worth it imo 🙌💪🙏

A lot more difficult than I expected.

Good grief I had no idea. I will look at cast pieces in a different light from now on. And a massive massive applause to there perseverance.

Well a few o bugger moments . Remember its a feature not a fault !! You guys are doing a great job . We all have out falures its how we deal with them .. Thats why you succeed !! We are all learning every day . Keeping our heads working . When most of us are past the best before but not the use by .. go for it .. hi from the land down under

Amazing skills

I love that he uses hand bellows instead of compressed air to blow the mole clean

Wishing you all the best guys. You have the determination so I'm sure you will succeed.

I have taken away from all of this capstan mold work is, "If it's so easy, go out and try it" ... Anyone else would give us a 30minute vid with everything working to perfection, but what would we actually learn from that? .... well, some would think "look how easy all that is, anyone could do that".... and that would be the wrong message and a disservice to the fans/viewers. I worked in a foundry in HS as part of a student trades program and remember pounding sand and pounding sand, and pounding sand....and even then, there's no absolutes dong the simplest castings with aluminum. When there guys started on the 3 part flask with those inserts I imagined a dozen ways this falls apart and fails and these guys know their shit.

Thanks, Steve !!!! ..... I've been waiting for this ! Maybe Clarke could use your help on more of his videos ... WELL DONE !!! -Ken ( long time subscriber to your channel and Clarke's ) .

I watched an old British documentary, where they laid out and pre-fabricated a switch lead for a very busy rail interchange. They cast their own specialty "Frogs." The greensand was all stored on the floor, they walked in it while making the mold, scooped up what they wanted from wherever they were standing. One of those workers couldn't have been older than 14, but he was in it up to his elbows. When it came to the pour, he was ten feet away. No glasses, no shielding, no leathers ... I assume it was "watch and learn" training for the day he would be in charge of that huge hanging crucible. Anyhow ... one thing I did see that looked like a good idea was that they had banked the mold on all sides with the extra greensand on the floor. It looked like good insurance against a blowout

This looks harder than I thought; great to see you guys get genuinely expressive and clearly it’s annoying. But the first thing he thought about was his friends travelling. I’m guessing they lose profit every time this doesn’t work out. Thanks for showing us this casting.

35:42 HeHeHe this sound reminds me of those Looney Tunes sound effects with the big bad wolf on his tippy toes 😂😂😂

I’m halfway through the video and am praying that you get a useable casting soon. An awful lot of work goes into this and I’m certain that many shops wouldn’t take this job on. I hope you are getting paid well for this. At first I thought when finished that the boat would be donated to the Albert Strange association, I didn’t realize this was going to be Leo’s personal boat. Wish the construction of my new house was being paid for by the public. 😃. Great work guys!

The whiny-ass tik-tok'ers ain't got a clue. Sir, you do what you do best. Pay no mind to the trolls and wimps. The rest of us understand. And appreciate the skill involved here. fjb

Hello Steve great video and the comment regarding floor pouring. Over here in the UK one of the very first cast iron bridges built in Coalbrookedale had over twenty feet lengths all poured on the floor. There is a very good documentary on television about the casting and a trial run was carried out on a mock build by the Army I think. Also there is a very early painting of the gorge with the original bridge in the process of being built

Just bloody excellent video. From AOB (another older bloke) 😅

Fail is an acronym for "First attempt in learning"

I saw something back in 1984 that illustrates why a dirt floor is good for a foundry. I saw a piece of red hot steel drop 2 inches on a concrete floor and a piece of the concrete popped out of the floor. It landed about 5 feet away after bouncing off the guy who was working on the piece of steel.

I have poured iron into green sand molds. It is very difficult. So many things have to be just right for it all to work.

The old adage of "try, try, try again" applies here. I know it's easy to be an armchair advisor on these things, but would seem to me, the complexity of the bottom of the part should have a lot more of the white separation powder (whatever its called). I'm happy to see that it looks like it does on the remaking 38:53. I watched SV Seeker learn the hard way on casting his own parts. He tried again too many times to count, way more than you did. However, he was experimenting with different sands, flasks, and heating methods. He was learning as he went.

Talk about hot stuff!

That is heartbreaking. Keep at it lads.

I seem to remember from high school metal shop days of putting sand retention cleats in the taller bowl shaped molds to mitigate the inside of the mold coming apart. I could be wrong.

"...heck, I even do dumb things - I started making RU-vid videos!" - That's when I hit subscribe. LOL.

Hope you got to lunch at 12:20. She meant it.

Looking at the capstan components, I am sure they could be milled from steel billet instead.

is there actually ANY shop in the world that could do this? Well I mean, SOMEONE cast the original. How did they do it? Appreciate the effort, and feel the frustration.

❤

Really makes you wonder how the original was cast a hundred years ago!

how does 3D printing figure into these types of processes?

Is it really only the 3:rd mold? It seems to me I've wathed a dozen videos where evertything that possibly could go wrong did. You guys must have the patience of a bunch of angels not to turn insane from spending 8 hours making a mold and then having it fail for some reason, and then having to re make it again and again. I get tired just watching the videos. Kudos for some great work.

My god why people just don’t ask how something is made

The sand needs to be fully screened and added and tamped in 1” layers. When you removed the capstan you can see the lumps of sand still coagulated in balls rather than a cohesive unit. Tamping fully screened layers should rectify your issue

At my age time is limited, so I watch most videos with long winded talkers at 1.25 or 1.5 speed, unless there's music, then I mute it and watch it a X's 2. 🤣🤣🤣

Steve, thanks for showing the whole process. Editing often makes these tasks seem much faster and easier than they are. I do have one question though., maybe I wasn't paying enough attention to your introduction.... are you implying that tik-tocers would benefit from pounding sand???

Just a thought, have you tried using one of those cement vibrators or dare I say some sort of vibrator that you could tape to the top and then pull it while it's vibrating. I was thinking maybe that would provide the consistant and even vibration that would allow the mold to release easier. Just a thought.

Commenter’s like to believe they are experts

Not sure why all the hate. I guess you can’t please all the keyboard molders out there. Oh well, as long as you got it done. I enjoyed watching it. I would like to know how you prevented it blowing out on the subsequent pour(s).

Suppose at some distant past it was the rocket science of its time

Why have you chosen to pixel blur part of the equipment?

Well now, I sort of feel short changed that we didn't get to see all of that tap-tap-tap-tapping. Over an hour you reckon. I would have watched that. And then making the new, new mould when that one failed. I would have watched that. It occurs to me that we will get to see you men working for at lest one more video too. I will watch that, also, and be right pleased to tell my growed children how long it took. " I was clean shaved and sprightly when we began..."

Surely it just bigger mold time? The original was over 100 years old…how did they make it?

Almost looks like you need some sort of mechanical lifting aid to handle that mold assembly, there must be quite a bit of weight there, looks really awkward.....

lol great trolling!!

28:16 Cast Iron...?? I thought it was made of bronze - No ?

Hi - I like your videos but I would like to request making a more condensed version.

I wonder how many tries it took the original foundry to produce a final casting.

WOW

Hey can you do me a huge favor? What size pants does clark wear? Im gonna buy him a new pair. Im not joking.

the original was made over `50 years ago, without the modern technology, and as part of a continual production line. what did they do differently..................

Does the black sand have the same properties as green sand, or is it something special?

3000°F = 1650°C 100 pounds = 45 kg

No, this isn't rocket science; it's more finicky. Rockets don't have so many things that can change for no reason.

I always wonder about these people that don't know the difference between production and custom. custom is expensive for a reason.

just curious how thick is the sand suppose to be between the wood and iron? y'all had a bear of a job there. i don't envy you your task ahead.

What is the white powder release agent between the molds?

You are 20 years younger when I play you on 1.5 speed .

Nice lathe, keep talking, I'm listening. I'm old too.

Did you get a good casting since this was made?

I wish you guys would stop saying cap stan, it is pronounced capstun, the a is silent.

This a very labor intense mold with means expensive.A gantry crane would be nice

Fascinated by what you guys are doing but hoping you can improve on the camera skills. It's hard to watch janky stuff or not see what's going on fully. My motto, as an indie film producer, is "follow the story." What's happening, let's see it, poke the camera in there! Thanks guys!!! 😊

I've watched several of these videos now. Do these guys know what they are doing? Because it looks like the blind leading the blind.

One suggestion I would have made is I would have drilled small pin holes in the wood mold to help elevate the vacuum of the wood and mold. The main issue with this mold seemed to be releasing the tightness of the sand without any vacuum release from the mold itself. Obviously, it appears you have achieved a good mold release in the last minute the video. But it was frustrating to see you and your crew struggle with this issue. Good work and thank you for your persistence!...in the end, ignore the internet and its criticisms! Anyways, congrats are in order!