Killer Efficiency Scrapping Aluminum

By Cressel

Your aluminum foundry operation should be efficient. Optimizing your feedstock pipeline is critical to profitable casting regardless the size of your foundry. Don’t let your process rob you of time or money. If you process scrap aluminum, you need to use the steps below to instantly improve your foundry’s efficiency. I go into detail below, but here are the […]

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Makecise Log – 20170402

By Cressel

This week I released the column assembly video, finished the ram cap pattern, finished the a ram pattern, cast the ram cap, cast the ram, and attended the Atlanta Woodworking Show. In case you missed it, I released Part 2 in the shaper series this week. Here is the video. I finished up the ram cap […]

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Shaper Column Front Casting and Column Assembly

By Cressel

As you know I started building a Gingery Shaper recently. In this part of the series, I use the lost foam casting method to create the column front. Then I add the vertical ways and assemble the column front. I now have the initial column assembly completed. Note that only two fasteners are used because […]

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Makercise Log – 20170326

By Cressel

Last week’s update: I ordered hardware for the project including fasteners, bushings, bushing stock, ANSI 35 roller chain, bull wheel sprocket, pinion sprocket, set screws, and shaft collars. I probably missed some hardware, but this should get me through most of the shaper build. I cleaned up the column sides and the column front. I scraped the […]

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Makercise Log – 20170319

By Cressel

This week’s update: I spent a fair portion of my time this week continuing the modeling of the shaper. I released the first video in the shaper project series. I purchased steel for the shaper and mill. I built a hot wire foam cutter and used it to make the column front pattern. I used […]

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Column Sides – Pattern Making and Casting

By Cressel

I have started the Gingery shaper project. I am following the instructions in the The Metal Shaper book; however, I will be adapting it to metric dimensions and with metric hardware–at least for the most part. I also know of at least a couple other departures from the design in the book that I am […]

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Makercise Log – 20170311

By Cressel

Gingery shaper column sides

In this log, I will discuss what I accomplished this week. I spent the majority of my time this week modeling the shaper. I also built an overhead hoist to help with molding particularly for the column side and other large molds. I edited and released a status update video. Finally, I cast the second of the […]

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Portable Lightweight Propane Foundry

By Cressel

Would you like to be able to melt aluminum anywhere? Well, I certainly do. I wanted to melt aluminum to demonstrate metal casting at Maker Faire Atlanta but did not have a feasible foundry in which to do so. My kiln would be too slow for regular demonstrations. My old kerosene foundry was languishing in […]

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Improving the Garage Light Controller

By Cressel

Garage Light image for openHab upgrade

In my original garage light controller post, had prepared a script to automatically launch the beagle bone black (BBB) web server. When I implemented the kiln controller, I also upgraded the garage light controller to interface with openHab. The new code for the BBB is in a zip file below. To run them, I just […]

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