![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicDD7VXi6PACOn8jjtGa672w9HbPdb83Zxx6F7kPNw18molrPdB3mlQvRXNMyU1VFOHDritz1Oq62DK21fZcQRRwmKupxgfQk-mXbWedkBXTftMbJ9tK9-cfXpYAJcR9QOJtTyx_q0Tddv/s200/aluminum+foundry%252C+jack+plane+handle+pattern.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqHYAY-mgSnLkM1L-ndSLIWEBzpn4R9v4ILzKz-MD3gRo4xEvNDDF8d_j2lmuIcgrzdyVseBj-fNeyUcC-2989UL5F47t_l3TFNovcfmlsbL8BnG-ErqEDrSmJg5EVEt9ZQoRzgGoBKI8H/s200/foundry+flask+sprue+and+riser+pattern+mould.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFSbuyseJzzgm0P9iI0Dd-I2l-vZHAlcNGV_6Grl7Tt_Ks0IF9A5ptb0ZAiFMAr4gUwF1G1Wcgt0tBGmVFOL3jgGbqde_aS8Fge6sMcWK4y-VJqxUYs-0u-xX8EirNP3iDbcDNPEQ3woAc/s200/aluminum+foundry+casting+cooling+in+flask.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkj4_VIs0YlJowFOvlNAW0IEA4o8bP3iQeTikFmJUAlMBdaUMVMTgkpx9nxLkIFbmoE4GvezH3zxEPYB4UV2eqS4LP9mdRrCnvQvL9tvqotI-W8AqXTgx3wPq4ZlFfm4gN_o58RTvBxVdn/s200/aluminum+foundry+flask++casting+sprue+and+riser.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpHeGR1EQcq7UnJi8cRBk7MjpOZlUhFVstpIy1iMbToR38yNh_tFnmF1GQMp5VjBfBPPxMhUF40glijyHEQ0qVNB1SEdTw7kSrsKUVedyRM37GORQM2FTTE20rFx1D0ZQUJRCplwNoyvZM/s200/aluminum+foundry+open+flask+casting+cooling.jpg)
The first casting was perfect my plan was to drill the bolt hole after the casting. The front handle drilling was accurate but on the back handle I drilled the wrong angle for the bolt to fit correctly. I experimented with different core types I didn't want to make the traditional sand core. The second and third casting of the core failed but on the forth casting I decided to use a 9mm diameter metal tube, 1.5mm thick and 6mm inner core diameter. I heated the metal tube before placing it in the flask and pouring the molten aluminum. This casting was successful.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjghg5WkD9L7atd6UQ1Jb7uuCHHendLcY3etp0qlGzKWdb1FJCrGchtMj_WNgnCTk7cnSpfzm2kCF9S3MOVe4yy_Ov44kApSFCLgJRGb96LL9ludHi_-zbFUUPYIYrA_-vwnWcaUXHHjZrK/s200/foundry+aluminum+handle+casting.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQl7QCg6sLekchoM9Dn87FnU5nvabGzDEd3joJqCQ0QnqB5-ADC4_ajzFBH7UN3CB1LjYDiZWyEIwD8wtRf9nXVB4Qxc7HrE7blgfgiVyFAqinzPGEsHEpyJfqNZoaDDIrIWgGO8XKfFId/s200/aluminum+foundry+casting+handles+with+sprue+and+riser.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKPF3rv4nxIY7NGAH5x3tTvYc-CPOWm5-hrijCxXwX5-N8CD3LJh6g12-TXcCmt_kzGy4ANbY9aUuevX9DqGktwEpraqoWbNz_pHJOwGe1WQcbKo7K9K6Ybeu1Kj57MaEM1khV4hm4VAE8/s200/foundry+flask%252C+cope+and+drag%252C+handle+pattern.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdVy_uHHQa3vWX84QkpWFQqXnCzvOTjba4Arzxm2eM1F4g4lmkPrJMMS-2sRyilCfQ0RBWJwtICUBnEaIeOOM8RUt2Kz1EONqOWbm4fzK423iYrgFM_KjLoPmguhUMrwEHjZ-BUQIzvUWS/s200/aluminum+foundry+pattern+impersion+in+sand+mould.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwKNZFSBcbbNCp9L6Q9suB0iT8ZrFcLqURV2VytRUQfkK1pVIko6pGtxO8iAahz9Bv9mWQialywSWXwJg_cnXtgc5QlKqFIFTaKe7mdO48VLo-U92YFaW6Kg59bYde6UHh5HtGtWAOM7ox/s200/aluminum+foundry+flask+shake+out.jpg)
Before I made the sand mould I reconstructed the broken end of the back handle. I used a filler and varnish to prevent the sand sticking to the pattern. I also used my foundry casting green sand and it proved again to be very suitable for this type of castings. I left a wide gating system and sprue/riser well and that prevented any casting defects. After the casting was ready I cut off the sprue and riser and drilled the bolt holes.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkaJlJM1HNJLeSOnsF4yL87HbcBuNj9ziTWZC0FxLnehqEBKkylpYZHeY0d7qFUojnhOidORfTEJsSy1ZPH-PxBIZSZMRjo05MNh5g3JD6tfpdI7qZk6xyWMZHdwtGKWTBtaeHG1WWSjSq/s200/aluminum++foundry+handles+sprue+and+riser+cut.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFci407aiQLjkP40-lqgPPfWoumWg1t8asJTAriY00pQDW8NEOd4r3tA6xdlvFB66ctsRfhXLZxVUKRRwvZn4AolYXfM6DRAh04Yi3L0g9Fl0nbAfQQbfhXWOnDtOTAh3-DqVbJQCtPObN/s200/aluminum+foundry+sprue+riser+in+green+sand.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiF9DCVzKWr-ptXsJnPDASy_tDV-1kW63uOQI0VCq52CWKoE3afM0ogLUOjHkGZvHO_C1YH8y7V8e9ZW8hgaKsXaWCEisAaITZqNbV9dBfUHleva0Uk6hoQdkpDGT9Ipb2I8mShR1s5Q9yS/s200/aluminum+foundry+casting+metal+core+with+sprue+and+riser.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdfFjvjGHh45J-96UACL_t071UYt3jnru5zkBVeUSHsSGCyCGnVFGvTo4wxCKhjH18EpwngpkjIwHI1BwSSwff2JPLu4R780jVg_tVPZ52Bst_QssE7n5fXy3jWGiqOePf4RqZZgizPVQR/s200/aluminum+foundry+drilling+back+handle+core.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyqFSbsT0YtqNkLIfS-H_1IcDWkOlgg70LA-z7I4MmbXlEEksnIqmtbNrjfiWAiFb5BZqrNIs6UBy-r_EZuv8zqzj5JyyEvyvzM28YvYqnL_2AEQbqZs-OhUvMYGZpIElu2_zPtnqmAZt-/s200/aluminum+casting+drilling+front+aluminum+handle.jpg)
In the next set of images you can see the unsuccessful handle castings back in the crucible for another remelting session. After the bolt holes where done I used my buffing wheel and polished the new aluminum handles.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigdd3erqtM6Q0Z_3-edfE14IQ6xpfnjzNClJCNcZRq11Vmt0D_-vxJE4PV8IS8Uq_pficVJUduduumA9RTOKnd1235KdVx_u9NshwRtUDM8-LKVT1rx5XFSN_aFU7UKqLuYspZdu9JfVWk/s200/aluminum+foundry+crucible.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcL4pGn_oGJgk5qkZF38k2D7j1SIA-ZaNmYUnLlcb6UCQ-we-xLsY09-InE8892v-Dh_HnNxIEX3XKKOlSfP4gh9FMIw-gEcib7uzIbx09tpuASYYR92DkDQ1It8-LlHtSKtQiNMvV6Pkl/s200/aluminum+foundry+casting+with+core.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEA-4JycmCWvkeP2Ee1ULDAr87dXjPU9sjUHJ3Q8mkduaKlgFEXBylkl4HRk2Dq6gfL-mmVV9OpP6iUMh15ZKUAaO4lIHHvHZ41KxGNY-86f6TOLyghBleN0fqAnDiCVjs6V6xy-AYhdEK/s200/aluminum+foundy+polished+aluminum+handle+casting.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglLU1ONhGBQwQWkzXjWGyK7SIjWnt4HNrqeaG1EV_436pZJ7hj6jh2cX9JzX8pdeDqr7BBbefWVeASL9TPHW7ycl9SxBVcY_0tifZnHTyKhbEu2blBM5j0EYkU2Vv7wMtfqx41BhDbOs1J/s200/aluminum+foundry+polished+aluminum+handles.jpg)
In the next images you can see the jack plane with the new front and back aluminum handles ready for use.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKl_zLCnugPBkoORF1chFQpnBRpBNrS1G3QN_DOlKTV2X-Q18w26iNk0SysrNVn92ubgaUOrrnLfKs1CwBeyuLjaOZLASP-ppAR-CAnUATZDQh4nXUyhgpD_z4H3LP1FqBqLVP5RQtRDRJ/s200/foundry+casting+aluminum+handle+and+broken+pattern.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivVDaJiGg7NO9crO4DlIm3juuWKRYoetlwpiIHelnnkeMH_p3uDDtv6kIxxhXskfLO4e9RQ5U6pUXxXRnfi1lUosLDso4qMwxu6kO4v7Saaenk7FepNfbvv3gajoqgOtP7wU2CiEPFBhP9/s200/aluminum+foundry+casting++plane+handles.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8xXGRCS1phCJlZ2OMkJOZm7T4EPE8ZU1IIfYmZ0VJG1B3ZKsttZmipIXBF9MytL241nXo-t5IUhoHtKQ27DQ7ISQ4IOJuV9rGjVbjV0u37UARFlFkXDLLGlNeCsDAfJ10_0f4SbX5qJpN/s200/aluminum+foundry++casting%252C+handles+in+place.jpg)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5XqPnNXt-nond6uMR3q1E5JhLNCTSGve3Yz-NZNaqu1o91TSSIAH-dDFtUAPYFPq5XSCG4oHLdGeAz8umN5B_65yZkU-GJRCw4QDXCHMb37PS7y3yiCnU1X0lzUY5B1thVCOKuv1iZ6fU/s200/aluminum+foundry+casting+broken+pattern.jpg)
27/03/2012
Today I was making a new pattern using my jack plane with the new aluminum handles first time. works great ;-)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6uRGDfrQYj7WijouT7d9lCrMyu4QB9N5TedyuR2CuAD99xtLCu5FuBx2WSMU7v6GW_2T80fWkf_kk_GVMl5FcveY9cLFgOiuvpLgH5y1ML3VCEdmFmzMAw1wXaDsxjoZjyH1Kd2QyFdIB/s200/aluminum+handles+first+use.jpg)