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Learn more at Author Central. Previous page. Kindle Edition. Next page. There's a problem loading this menu right now. Learn more about Amazon Prime. Get free delivery with Amazon Prime. Books By David J. Charcoal Foundry, the first book in the "Metal Working Shop From Scrap Series", gives you plans for building a metal melting furnace and instructions on basic pattern making and molding.
All the information needed to set up a foundry in your work shop can be found in this book. Simply stated, 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.
The main ingredient in these projects is scrap aluminum and pot metal. The only tools you need to get started are ordinary home shop hand tools, many of which are probably already in your possession. Much of the remainder is found as salvage or cast-off and little expense need be involved.
The charcoal foundry is simple to build and operate and the initial cost is so low that it can be in the reach of nearly anyone. And the fundamentals of pattern-making and molding are easily understood and mastered.
Once you have built the charcoal foundry and the metal lathe in book 2, there is little beyond your reach by way of shop equipment. Build as large or small as you wish and you are your own parts supply company.
If you already have some machine shop equipment, you will find that adding a foundry to your shop greatly expands your capacity. Being able to produce your own castings for accessories and equipment is a great advantage. Design your own, make a copy or follow a plan. It's easy when you're in control and can produce your own castings.
Other Formats: Paperback. Build your own Metal Shaper. Exotic is a mild adjective when applied to this shaper. It will cut splines, keyways, gears, sprockets, dovetail slides, flat and angular surfaces and irregular profiles. And all of these with a simple hand-ground lathe tool bit. Obsolete in modern industry, of course, because milling machines do the work much faster and cheaper. The shaper has a 6" stroke and a mean capacity of 5" x 5", variable and adjustable stroke length, automatic variable cross feed and graduated collars.
You will be proud to add this machine to your shop. Especially designed for the developing home shop. Extremely rigid and versatile. Eight speeds from 43 rpm to rpm. The spindle raises as much as 6" above the work table and the transmission is designed to follow the vertical travel without straining the column or changing the belt tension. Accessories included in the project are angle plate, face plate, fly cutter, tail-stand and compound slide assembly with which you can do large swing lathe jobs.
Still no need to look for outside help. Dave designed this furnace especially for the home shop foundry. Very quiet in operation. Easy to light and simple to operate.
The body and lid raise for safer crucible handling. Operates on natural or bottled gas. Costs only a fraction of the price of a commercially built unit and it will melt aluminum, brass and even gray iron.
This project really proves the worth of a simple lathe fitted with only a face-plate and centers. Now that you have a machine shop you need accessories and tooling. 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 years ago made his handful of tools do any job he was assigned to do. I almost left this one out of the series and I would have if it were not for my friends who tell me they are always wanting to bend some sheet metal for a project. This one uses no castings. Its a 15" brake as detailed but you can scale up or down in size within limits.
Definitely not a heavy duty brake but you can make neat bends in 26 gauge metal to form duct, boxes, drawers, belt guards and dozens of items for your shop projects Some have beefed up the leaves and pivots so that metal as heavy as 20 gauge can be bent sharply. If you have done the projects progressively as the author did you will have done all your drilling with an electric hand drill up to this point.
In fact it would not make much sense to proceed to the deluxe accessories without one. You could buy one of course, But anyone could do that Two stage speed reduction gives a low speed of rpm for serious large hole drilling.
Ball bearings in spindle driven pulley and idler make it smooth and quiet running. Quill feed is by cable or chain drive so there is no rack and pinion to cut. Sheet Metal Technology Jan 21, Subjects covered are safety in the shop, use of tools, layout and pattern development, various ways of forming and joining metal along with edging methods, corner systems and panel reinforcement. You will be introduced to the basic sheet metal shop where you will learn about various methods of forming sheet metal and in some instances even constructing your own tools including a rather unique and functional 24" sheet metal brake constructed of hardwood.
The final chapter opens with a mass production operation set up to demonstrate the efficiency and economy of modern industrial technology. Then further projects are progressively introduced as skill is acquired.
Such projects as a dustpan for the shop, a handy tool tote tray as well as plans for single and double hinge tool boxes. By this time you are an advanced student and ready to construct the unique portable charcoal grill and the impressive three drawer tool chest from the plans provided.
Dave Gingery brings it all within your grasp and you will be amazed at what can be produced with tin snips, standard measuring tools and a 24" sheet metal brake.
Other Formats: Perfect Paperback. If your hobby is amateur radio or electronics you will often need coils in a variety of size, type, specification, etc.. Coils are no longer as easy to find as they were 20 years ago so you will have to wind your own. And the mechanical counter gives you total control of accuracy.
Build Inexpensive Powerful Blowers For Many Uses Build a Dust precipitating cyclone, design sheet metal transition pieces, balance a dust collection system, build a static balancing stand and more.
Learn how to build a simple manometer and pitot tube and actually measure and fine tune your custom air system. This book will show you how to take pillow blocks, shafting, plywood, sheet metal and other common materials and build a dirt cheap blower that will outperform just about any make-do blower you might find on the surplus market.
Let Dave Show you how easy it can be to design a fan that will provide the volume and pressure you need for the system you are building. Li'l Bertha is Dave Gingery's eighth book and was originally published in by Lindsay Publications.
This second edition has been published by David J. Gingery Publishing, LLC. The book Li'l Bertha describes the construction of an electric furnace that can be used as an alternative to a charcoal or gas fired foundry furnace. Although designed with the foundry in mind, the general design details can be adapted to a wide range of furnace needs from creating ceramics to heat-treating to calcining of investment molds and more.
How to Build a Magneto Magnetizer Jul 11, 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. More Information. Anything else? Provide feedback about this page.
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David J. Gingery is most famous for his Build Your Own Metal Working Shop From Scrap series, which details how to build a reasonably complete machine shop at low cost, often from scrap metal and other items. The hobbyist starts by constructing a small foundry capable of melting silicon - aluminum and zinc alloys from recycled automotive parts. Then green sand castings are used to make a metal lathe. The lathe is the first machine built since it can be used to help build itself. The lathe and foundry are then used to make more complicated machine tools.
David J. Gingery
Books by David J. Gingery