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    Casting alloys have different properties than...

    Casting alloys have different properties than wrought alloys. One of those properties is fluidity when pouring.
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    OK, Now I see what you are doing. I would weld it...

    OK, Now I see what you are doing. I would weld it up, drill the bushing holes as accurate as possible and try to assemble. If the slider won't slide, determine which hole(s) are causing the bind,...
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    Zap, I hate to say this, because you are "trying"...

    Zap, I hate to say this, because you are "trying" and that is what it is all about, but I think you are going way outside of your fabricating abilities here. If you are trying to weld steel plates...
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    Historically these windshields are cast in pieces...

    Historically these windshields are cast in pieces and welded together.
    Go to Google images, type in Hallock windshield.
    22275 22276 22277
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    You have a long thin part that is constrained at...

    You have a long thin part that is constrained at each end by bonded sand, something has to give, how can you avoid hot tear. This looks like a worst case scenario for hot tears
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    I would never try to mold that in resin bonded...

    I would never try to mold that in resin bonded sand, but if the foundry plans to do it that way, one pretty much has to let them try. (On their dime) Don't let them destroy your pattern and don't pay...
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    If I were to move, I don't think 4, 53' semi...

    If I were to move, I don't think 4, 53' semi trailers would hold it all. (I don't have parents anymore, so I don't have the luxury to leave stuff behind)
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    I learned in a 1 semester tech school course. All...

    I learned in a 1 semester tech school course. All they taught in that amount of time was 6011, 6013, and 7018 in all 5 positions. I could have gone to Alaska and welded on the pipeline after that...
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    Zap, I've never used a small flux-core (Known in...

    Zap, I've never used a small flux-core (Known in the industry as inner-shield) machine, but I use a 120V mig all the time. Best way to weld material heavier than it is speced for is to weld "vertical...
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    Yes, you would need a patent before anyone would...

    Yes, you would need a patent before anyone would pay you for a licensing agreement. You might be able to get them to buy your idea, (because you have obviously done work on the design that they won't...
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    Hey Zap, somehow I thought we were talking about...

    Hey Zap, somehow I thought we were talking about a 1" hole. Being 1 3/4" I would go the local machine shop route, because I think they will do it cheaper than the price of the drills you need, and I...
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    The last time I moved I really enjoyed it!...

    The last time I moved I really enjoyed it! Thankfully that was 41 years ago and we were moving (from a hellhole where the land lady let herself into our apartment every day after we left for work) to...
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    Let's not get carried away with $500/hr machine...

    Let's not get carried away with $500/hr machine tools, who's capabilities far exceed the requirements of the job. Step drilling will get the job done!
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    Going to be a real problem getting a patent that...

    Going to be a real problem getting a patent that will stop Jim's production, the legal proof is right here in this thread. They might be able to come up with some whiz bang idea, to get a patent, but...
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    If your holes are a standard size and you have a...

    If your holes are a standard size and you have a way to turn a drill slow enough, buy 2 drills, one finish size and one a 32nd smaller, drill a pilot hole then the 1/32 under size, (if short on power...
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    Looks to me like someone (you?) made a...

    Looks to me like someone (you?) made a mock-up/prototype expecting it to be a pattern. (It ain't) The next step in the manufacturing process is to make a real pattern, and it is complicated. Figuring...
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    Zap, it depends on what you are doing. Lathe,...

    Zap, it depends on what you are doing. Lathe, mill? What size?
    For a lathe: I don't recommend spending big bucks on a base, unless you plan to use it every day making your living. (even then I made...
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    My son does a lot of free lance photo/video work...

    My son does a lot of free lance photo/video work for various Chambers of Commerce tourism bureaus in Michigan's U.P. A big thing up there is to ride these bikes on the Nordic ski trails in the...
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    I personally hate that single locking knob, most...

    I personally hate that single locking knob, most of the time you will want to loosen one arm only, not both. Now for your question; that clamp is for the small dovetail style indicators, not the 2"...
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    Sticky: I use reserves, but only about 3" tall. These are...

    I use reserves, but only about 3" tall. These are used more as a means to use less sand in the cope. (no need to have an 8" thick cope for a 1" thick part) I don't have much trouble filling my simple...
  21. If you are going to build an engine, I guess a...

    If you are going to build an engine, I guess a straight 8 Bugatti would be pretty close to the top of the mountain. BTW, I wonder what the price on a brand new Bugatti block would be? (just in case...
  22. As I first read your original post, I thought...

    As I first read your original post, I thought maybe too much zinc in the mix of "scrap from work." I don't think there is much zinc in cans, but charcoal is tricky. Hairdrier could be too much air,...
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    I'd try high temp nickel anti-sieze! Rust creates...

    I'd try high temp nickel anti-sieze! Rust creates a jillion pits in the part for the rust particles to lodge in.
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    So, you want to make holes in your furnace to let...

    So, you want to make holes in your furnace to let in cold air to make it hotter? Somewhere there is a better way.
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    Found the one that I was thinking of....

    Found the one that I was thinking of. http://www.aircraftspruce.com/catalog/cspages/evershield.php
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