If you can build a sand castle or make a mud pie you can make a sand mold to produce castings for your metal shop projects. It really is cheap and easy with a simple solid fuel furnace. Here are plans to build the melting furnace and instructions for basic pattern making and molding to get your shop project under way. Charcoal is the fuel and aluminum and zinc alloys are the metals to cast. None of the pulsation or roar associated with gas fired furnaces. Build your own molding bench and flasks. Make your own melting pots and most of the simple tools required. Discover how cheap and easy it is. Even if you already have a lathe and other equipment this simple foundry setup will greatly expand the capacity of your shop by providing you with a supply of cheap castings for your projects. Discover why so many shop hands say "Metal Casting has opened a whole new world of shop experience". Heavily illustrated with many photographs that will show you step - by - step how to build a foundry.

The Charcoal Foundry (Build Your Own Metal Working Shop from Scrap, Vol. 1)

Crafts, Hobbies & Home

David J. Gingery

Crafts & Hobbies

David J. Gingery Publishing, LLC

Using castings from your charcoal foundry (see Book 1 in the series: The Charcoal Foundry by David Gingery) and simple hand methods (no machine tools needed!) you can build a sturdy and accurate bed for a metal lathe. Then additional castings, common hardware items and improvised equipment will add the headstock, tailstock, carriage and all the remaining parts to complete the lathe. Illustrated with photos and drawings to show you all you need to know about patterns, molding, casting and finishing the parts. The lathe specs. include a 7" swing over the bed and 12" between centers. Adjustable tailstock with set-over for taper turning. Adjustable gibs in sliding members and adjustable sleeve bearings in the headstock. A truly practical machine capable of precision work. Once you have a foundry to cast the parts and a lathe to machine them you can tackle more exotic projects.

The Metal Lathe (Build Your Own Metal Working Shop from Scrap)

Gingery, David

The Metal Shaper

Book by David J. Gingery, Gingery, David J.

Milling Machine (Build Your Own Metalworking Shop from Scrap Series)

Gingery, David J.

The Drill Press

The Dividing Head is also known as book 6 from the best selling 7 book series, 'Build Your Own Metal Working Shop From Scrap'. This project really proves the worth of a simple lathe fitted with only a face-plate and centers. You'll make some valuable accessories for the lathe and you'll be a better machinist when this one is done. Now that you have a machine shop you need accessories and tooling. You also need practice on your new equipment so here's a book full of projects. Build a four jaw chuck, a steady rest and other useful tooling. Build a worm-wheel dividing head and add change gears to the lathe so that you can cut accurate screw threads from 8 to 80 per inch, both right and left hand and internal and external. Make your own reamers and learn how the master machinist of 100 years ago made his handful of tools do any job he was assigned to do. These are all items that many of us can't afford early in our shop careers, but you can make them yourself now that you have a machine shop.

The Dividing Head & Deluxe Accessories (English and Spanish Edition)

Designing and Building the Sheet Metal Brake

If you have a particular interest in magnets, you can build this simple device to create new magnets and recharge weak ones. Although specifically designed to recharge magnets used in engine magnetos, this device can be used for producing or restoring magnets in a great variety of shapes and sizes so long as they are made of alloy steels. This is a relatively simple device. Only ordinary mechanical skills are required to build it. The metal core however is of very heavy steel and some machining operations may be required.

How to Build a Magneto Magnetizer

David Gingery

Build the rare and unusual Atkinson Cycle engine. It had to be an unusual engine. After all, Atkinson was competing in the expanding small engine market against Nicolaus Otto's newly developed four stroke engine. Otto held numerous patents that virtually eliminated all competition. To avoid infringement, Atkinson was forced to create a completely new approach to internal combustion. When you build this engine you will quickly appreciate how creative Atkinson was.
We have found that wherever we show this engine people are amazed and fascinated by it. They ask. . . Where are the timing gears? What about a separate cam shaft? How does it run? How can it complete four cycles in a single revolution of the crankshaft? Are you sure it is not a two cycle engine?
We smile and explain that the secret lies in the unusual design of the crank linkage which, believe it or not, allows the exhaust, intake, compression and power strokes to be completed in a single revolution of the crankshaft. The cams are located on the crankshaft, eliminating the need for timing gears and cam shaft. Simplicity adds elegance to innovation.
 Inside this book you get step by step instructions showing how to build the Atkinson Cycle engine as designed and perfected by Jim Lewis. Castings are suggested for the base, flywheel, cylinder head and crank linkage but none of these parts are so complex that they could not be made from stock material. A lathe milling machine or milling attachment and other tools one would expect to need in a project of this type are required.

Building the Atkinson "Cycle" engine (The Gingery engine series)

Vincent R. Gingery

Bending a piece of pipe is often easy enough, but the real challenge is in bending it to a nice even radius without kinking or flattening it at the bend. To achieve consistent and professional results you need a pipe bending machine and that is what this book is about. Here you will get step-by-step instruction showing how to construct a very simple machine capable of bending a radius in pipe to any desired angle of from 0 to 180 degrees. And with the proper dies, solid round rod, flat bar, and square tubing can be formed as well. The frame of the machine is build entirely from easy to find, 1/4” x 2” h.r.s. flat bar. Other things you will need are a welder to assemble the frame, a few common hand tools, a drill press, jig saw and a few nuts and bolts that are easily found at the hardware store. You will discover how easy it is to construct bending dies made of hardwood. And you will be amazed to see how well they perform. Dies can be made to bend any size pipe you might want up to the 1” diameter capacity of the machine. Need a larger capacity? Consider scaling up the design and building the machine from heavier material. Build a pipe bender today and discover what a little leverage and a couple of bending dies can do for you. It’s a simple design and an easy project to build. The end result is a compact, attractive machine that mounts nicely at the end of your work bench.

How to Build a Pipe Bending Machine

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Books by David J. Gingery Publishing, LLC