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The first core box section for the motion cylinder in the gluing jig. This will be in for a day in order for the glue to set. Meanwhile Tony now has to build his routing jig to form the core box to the final profile.
The first core box section from the gluing jig
March 2021. Tony now needs to build the routing jig. This needs to hold the core box section in place and support the routing jig. First, a framework is attached to a baseboard to support the edges of the routing jig. The outline of the core box section is drawn on the baseboard. Tony will fit pieces of scrap here so that the section is held firmly in place.
The section sits in the jig like this
The routing jig sits on the top.
The routing jig will be fixed to the core section with a couple of screws to prevent any movement and then routing can start. Tony will then start his production line.
Just in case you are wondering what we're trying to produce, hopefully this will help. On the right is a blastpipe core; produced by packing foundry sand into the core boxes on the left. When placed in the casting mould, this will form the air space in the centre of the blastpipe. It will be supported in the mould by "prints" which are recesses left by the main pattern. Obviously the core box needs to be in halves so that the core can be extracted. Tony is making the core box as a set of sections which will be glued and fastened together. He has contemplated a number of ways of tackling the problem but believes that this is the best solution.
Once the section comes out of the gluing jig, dowels need to be fitted to give it additional strength. Here are 3 blanks in the vice and the dowel holes have been drilled.
The dowels are fitted like this and are then glued into position
Tony now has a production line building up. Top left are 2 blanks for the motion cylinder core completed and sitting on the shelf. Bottom left is a blank, work in progress. On the shelf down from the top are 7 blanks which have been glued and dowelled ready for routing.