Author Topic: 1/4 Scale Ford Cosworth DFV  (Read 4324 times)

Offline Ye-Ole Steam Dude

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Re: 1/4 Scale Ford Cosworth DFV
« Reply #15 on: July 31, 2018, 09:10:59 PM »
Sure like that finish.

Have a great day,
Thomas

Offline Roger B

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Re: 1/4 Scale Ford Cosworth DFV
« Reply #16 on: August 01, 2018, 09:04:23 AM »
Excellent models  :praise2:  :praise2: Have you identified a suitable casting company. Vixen ended up using a London jewellery company to cast some parts for his Jupiter radial engine.
Best regards

Roger

Offline JonC

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Re: 1/4 Scale Ford Cosworth DFV
« Reply #17 on: August 01, 2018, 10:44:21 AM »
Thanks Roger.

Before I go out for casting I need to simplify the drawings ie remove oil journals, holes etc and add on some machining stock.

Sounds and looks like the company used by Vixen is the best place to start.

Jon
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Online steamer

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Re: 1/4 Scale Ford Cosworth DFV
« Reply #18 on: August 01, 2018, 11:11:56 AM »
Jon....I would read up on Vixen's posts on his W165.   He had issues with printed masters....

Dave
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Offline JonC

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Re: 1/4 Scale Ford Cosworth DFV
« Reply #19 on: August 01, 2018, 12:04:57 PM »
Hi Dave,

Thanks, I'm reading my way through the W165 and will look out for that.

Unbelievable workmanship.

Convincing myself that going the casting route is justified by maybe a commercial interest for castings  :-[

Jon
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Online Vixen

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Re: 1/4 Scale Ford Cosworth DFV
« Reply #20 on: August 01, 2018, 12:35:58 PM »
Hi Jon

Sorry to correct Dave, but the lost wax casting stuff is in the "By Jupiter" posts.

For all my lost wax foundry work I use "justcastings. co.uk". They produce very good castings, they have a quick turn round, the cost depends on the size of the object and the amount of metal consumed. Have a talk with a guy called Theo at Just Castings Ltd. Tell him Mike sent you.

If you read the "By Jupiter" posts, you will see I make my waxes from a silicone mould. You should allow a 2.0% shrinkage allowance for the investment casting process.  There may be an additional "print" shrinkage allowance ( the equivalent of my "silicone mould" shrinkage allowance). You will have to do some test prints, in wax, to determine this value. You should then be able to scale up the individual piece parts your 3D model by the required amount before you print the waxes for the foundry.

Mike
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Offline JonC

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Re: 1/4 Scale Ford Cosworth DFV
« Reply #21 on: August 01, 2018, 12:43:29 PM »
Hi Mike,

Thanks for the clarification.

Brilliant work by the way.

Jon
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Online steamer

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Re: 1/4 Scale Ford Cosworth DFV
« Reply #22 on: August 01, 2018, 12:44:12 PM »
Justifiably corrected....Thank you MIke

Dave
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Damned ijjit!

Offline JonC

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Re: 1/4 Scale Ford Cosworth DFV
« Reply #23 on: August 01, 2018, 01:10:11 PM »
Hi Mike,

You made the Perspex parts to make the wax mould to make the castings.

Have you or do you know if anyone has tried the more direct approach of lost PLA or printing the part in wax?

There are several tricky area's where you wouldn't get parts out of the mould ie the web on top of the block and the water jackets either side.

Thanks

Jon
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Online Vixen

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Re: 1/4 Scale Ford Cosworth DFV
« Reply #24 on: August 01, 2018, 01:26:32 PM »
Hello Jon

I went the master pattern and silicone mould route because I did not have access to 3D modeling software and a friendly 3D printer to help me.

If I were to do more investment casting, I would try the 3D model/ printed wax route. It would certainly cut out a lot of hassle in producing the waxes.

Why not make a simple (small) test piece and give it to Just Castings. I am sure they would be happy to try a lost PLA or lost Printed Wax casting for you.

Take this one step at a time and tell us how you get on.

Mike
It is the journey that matters, not the destination

Offline JonC

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Re: 1/4 Scale Ford Cosworth DFV
« Reply #25 on: August 01, 2018, 01:47:22 PM »
Thanks Mike, will do.

I have my own printer now so would be happy to help anyone else exploring this route.

Jon
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Online Vixen

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Re: 1/4 Scale Ford Cosworth DFV
« Reply #26 on: August 01, 2018, 02:04:21 PM »
Hello Jon,

The water cavities and the top deck would be difficult from a solid master pattern but dead easy for a printed wax.

You may need to consider how the investment in the cavities will be supported during burn out and casting. Many full size engine blocks had 'core prints' through the casting walls to support the internal parts, these were later sealed off with metal core plugs (domed discs).

What 3D printer do you have? Can it print in wax? 

Many of the commercial print houses now offer printed wax, and usually to a much finer surface texture than possible with a hobby printer.

Mike
It is the journey that matters, not the destination

Offline JonC

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Re: 1/4 Scale Ford Cosworth DFV
« Reply #27 on: August 01, 2018, 02:51:26 PM »
Mike,

I assume for the block, core prints wouldn't be necessary as the web cavity and water jackets would be connected to the outer shell of the mould so these are for area's where the cavity is essentially in fresh air after burn out?

Another issue with wax printing is support in areas like the web. I'm not sure that you can print support for wax and then remove it effectively. it might be that I have to split the block into various sections that can be printed without support and then glue/melt them together.

All a bit of a learning curve but that's half the fun.

Printer is a Prusa i3 but PLA, ABS, TPU only.

Jon
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Online Vixen

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Re: 1/4 Scale Ford Cosworth DFV
« Reply #28 on: August 01, 2018, 03:52:20 PM »
All a bit of a learning curve but that's half the fun.

I think it was President Kennedy who said " We do not chose to go to the Moon because it is easy, but because it is hard, because that goal will serve to organize and measure the best of our energies and skills."

Same goes for model engineering, when you are exploring something new and different

Mike
It is the journey that matters, not the destination

Offline JonC

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Re: 1/4 Scale Ford Cosworth DFV
« Reply #29 on: August 01, 2018, 08:22:40 PM »
Hi Mike,

On the W165 what are the non scalable area's that you have had to work around.

The engine looks very true to life but I guess there must be area's where it isn't possible to keep it that way ie cylinder liners?

Also I assume you don't have full dimensional drawings of all the components so how have you worked out what to work to ?

Jon
It's not what you know, it's not who you know.
It's what you know about who you know