Introduction: Air Cooled 2 Stroke Cylinder Head Using Shell Casting
Not Long ago, we decided to make a custom air cooled cylinder for a two stroke engine that we're developing.
We decided to use Shell casting, mainly because we'd never done it before.
Step 1: Patterns and Sand Box
First we CNC machined some patterns and some boxes to hold the sand
Step 2: Shell Sand Mold
Heat the pattern and invert the sand over it. The sand is coated with a thermoplastic resin that binds together and forms a shell. This is used as the mold to pour the aluminum
Step 3: Make the Castings
Pour the aluminum. fettle and shotblast
Step 4: CNC Machining
Machine the Cylinder head to fit your engine
Step 5: Fit on Engine
We have a be nice policy.
Please be positive and constructive.
No, you are making near net shapes by casting, the time to machine the final details is a LOT less than the cost of milling the fins for example.
If you have a CNC machine, wouldn't it be easier to use Billet Blanks or Pour your Scrap Aluminum into Blocks and then just Machine them into Heads? Depending on the Size of your CNC Table, you ought to be able to setup anywhere from 3-6 Heads to be machined. You can Cut Flat Raw Stock on a cheap Table Saw with the right Blade. What CR are you using on that Head, and what Bolt Pattern? What do you charge for them in USD? You ought to make some Rotax 277UL(26hp@6250rpms) Single Cylinder Engine parts, Head, Cylinder, Case. Head/Cylinder use's a (4) Bolt Pattern based on a 100mm Bolt Circle. They use 8mm Studs. What CC is your Engine and Hp@rpms? What is it for?