self-cast carburetortop for the TEN

Well done Marcoten, I've often thought a Chinese backyard foundry could make those pesky and hard to find Ensign carburetors for about $3.69 if they had a good sample to start with, and we ordered 50,000 of them, probably only cost $9.99 if we ordered 100 of them!:lol
regards
Mike

Looks Good,
I made one out of a block of aluminum.

[quote="MARCOTEN"]because the original top from the carb was broken, and a new or 2nd hand-one was not available or very expensive, i cast myself one from aluminium, and machined it down.
on the last picture you can see it mounted and the engine runs fine with it!
[/quote]

Hi Marcoten,
That's a high quality piece of work there.
I'm curious as to how you made the pattern and what material you used for the mould.

Looks Good,
I made one out of a block of aluminum.

[quote="chriscokid"]Looks Good,
I made one out of a block of aluminum.[/quote]

Erik, how did you affix the bronze thread into the aluminum block?
Cheers,
Neil.

[quote="chriscokid"]Looks Good,
I made one out of a block of aluminum.[/quote]

Erik, how did you affix the bronze thread into the aluminum block?
Cheers,
Neil.

all thanks for the replys,
@gauntjoh: for the pattern i used the old carbtop, i glued it back togetter and put some extra filler on it , specialy on corners to avoid the original squere corners, i made them a bit more round for more strengt and avoiding breakege later, also on the place where the fuel enters i made it a bit thicker for this reason.
i made the entrance of fuel not like original as that was a reson that many tops broke because it used to leak and then by trying to tighten it up to avoid the leaking the tops broke
i cast the extra hub on it for making it possible to put it in a lathe and machine it.

As a mold i used fireproof cement as i didn't have real molding sand.
First i tried several other materials like sand, oily sand, sand with cement, and several others, but that didnt had the good results for me.

the white stuff on the mold is a bit quick plaster as there broke a little piece of when i removed the pattern, and i repaired it.
the first casing in that mold didn't succeed, as there was still too much water in the hardened cement (even i left the mold on the bbq for 1 hour) there became steam/gas bubbles in the casting, so i did it again and it was ok now.

for heating up the aluminium i used my propane oxygen torch, but with a bit more propane then a flame for cutting.
it took me a lot of days to make it, but it was very nice to do and with a nice result!

[attachment=15035]DSC01896.jpg[/attachment]
[attachment=15036]DSC01893.jpg[/attachment]

[quote="MARCOTEN"]all thanks for the replys,
@gauntjoh: for the pattern i used the old carbtop, i glued it back togetter and put some extra filler on it , specialy on corners to avoid the original squere corners, i made them a bit more round for more strengt and avoiding breakege later, also on the place where the fuel enters i made it a bit thicker for this reason.
i made the entrance of fuel not like original as that was a reson that many tops broke because it used to leak and then by trying to tighten it up to avoid the leaking the tops broke
i cast the extra hub on it for making it possible to put it in a lathe and machine it.

As a mold i used fireproof cement as i didn't have real molding sand.
First i tried several other materials like sand, oily sand, sand with cement, and several others, but that didnt had the good results for me.

the white stuff on the mold is a bit quick plaster as there broke a little piece of when i removed the pattern, and i repaired it.
the first casing in that mold didn't succeed, as there was still too much water in the hardened cement (even i left the mold on the bbq for 1 hour) there became steam/gas bubbles in the casting, so i did it again and it was ok now.

for heating up the aluminium i used my propane oxygen torch, but with a bit more propane then a flame for cutting.
it took me a lot of days to make it, but it was very nice to do and with a nice result!
[/quote]

Bedankt Marcoten,
Casting with aluminium is something I've often wanted to try, I've just never had a good enough reason to have a go. I think your experience will spur me on to try it out sometime soon.