I'm getting into green sand casting of aluminum and zinc. My home foundry is going to remain a small 2-3 man operation. I want to cast a 1 piece blower intake for my /6. My question for you is how do I cast intake manifolds. What did you use for patterns, cores, etc, and how did you make them? Eventually I would like to cast my own block and head, just to see How much weight I can shave from the Swinger. I'm not looking to go into business. I just want to be able to have things that are not available in the aftermarket.
BTW, the reason I got started in metalcasting was partly to build my own lathe and horizontal mill, partly to replace a broken bracket on my dad's Gremlin, partly to make parts for my Dodge, and partly to make use of all the cast aluminum scrap I've accumulated. Any help is greatly appreciated.

fortj3@outdrs.net

Sand casting is not that hard, making the patterns needed to make the casting molds (green sand molds) is complex and time consuming.
It would be best if you get a book and read-up on sand castings and pattern making, then go talk with your local foundry. (Have them show you around and show you some patterns) As for some additional detail as questions come-up.

The pattern and core box can be made from just about anything. (I use wood and bondo)
The main trick is to be able to plan ahead and build an oversize pattern so it will shrink into the proper size. You take your best guess on the amount of shrink and build you pattern, cast a sample part, measure and adjust untill it's correct.

As I said, the process is somewhat time consuming.
Here is a link / look at a recent casting pattern I made for a cast steel SL6 roller cam. I have about 45 man hours of work into this pattern.
DD


Casting Pattern Example

Sounds interesting, keep us posted. Casting is one
of the projects that I have on the back burner. There are a lot of casting resources on the Internet.