Nothing a file can't fix

 Here you can see the core piece.

And I'll need to file away where the mold broke a little, but I expected that.

Pouring pullies

 That's hot. Just one mold to pour. From heat on to pour is about 12 minutes.

The pour went well, have to go out now, I'll knock the casting out later. The cake tin is perfect for any left over metal.

3rd attempt at pulley mold came out okish

These latches are great for holding the mold closed.

 

Drag done, 

Blowing out the sand from the holes for the locating pins.

Sifting sand on for a smoother first layer.

Ramming the sand, with a home cast sand rammer

First attempt

All went pair shaped when I tried to remove the patterns.

The simple shape was fine.

Changed to some other sand, not as fine, but higher green strength.

Not too bad

Core in place.

But the sand was too dry.

Mixed in a little more water and tried again.

 

A 3d printed core box and the core

 I don't like 2 piece core boxes made on 3d printers, the layer lines make separating the halves too difficult, and I have lost too many cores.

3 or 4 parts, with interlocking ridges, or pins work better for me.

This is a core for a stepped pulley, pics of the pattern, and mold should follow soon.

A little protection from splashes?

 Overlapping leather, perhaps if there's a splash, this will help reduce the damage?

Hopefully I won't get to test it.

Gingery Lathe Countershaft

 This is a quick shot of the temporary head stock running with the countershaft. It's all screwed down to the workbench.

Link to video

Just some photos