Manual Machining for the Casting Pattern

These are the first and second sand casting patterns made. These are right and left hand parts for mounting the caliper and steering rod connection bracket.

Both are machined from aluminum blocks. These parts required 27 setups each on the mill. Cranks had to be turned the right way for over two weeks. All vertical surfaces have a two degree draft and shrinkage allowance all over. This is the “Old School Method” and it is not fun. The older folks say mahogany patterns worked better.

The New School Method is a 3-D Printer. New and different processes are being developed by some companies. The 3-D printer is not a leap of fate. We have made test prints for some patterns. It is quite remarkable. The patterns can also be printed at a reduced scale. These patterns require very little surface finishing. To make a pattern change requires fixing the drawing and sending it to the printer. Then “Woo-ha”, a new pattern. No cranks. Automatic Machining centers are being built to finish the parts.

The capability of the 3-D printer is remarkable. Thanks to all the people that believed in this process and built a working model.