In our previous post we chronicled one of the last days at Imbleau's Iron Foundry in Renfrew. Their last pour was on the following Tuesday, February 7th, 2012.
Our post prior to that were a set of instructions for making the green sand mold to pour the corner lantern brackets. Here's what the casting looked like about an hour after the molten iron had been poured into the mold at Imbleau's.
Just to recap on the process, we started off with an original casting that we had to duplicate. The hollows and holes were filled in by Jedi Master Ross producing the following pattern.
Of course, the fun had only just started. First step was to drill out the holes for the mounting screws. While most of the 24 holes (6 castings x 4 holes per casting = 24 holes), there were 4 holes that wouldn't centre. A bit of grinding with a Dremel solved that problem.
Next up was to grind off the flash and the rough spots. One thing I discovered was that the sand cores were a bit loose in the green sand mold with the result that we had an extra bit of iron in the flash. Next time, we'll have to make the sand cores so that there is a tighter fit. Oh well, that's one lesson learned, eh!?
And this is what the final product looks like before Master Painter Charls gave them three coats of paint.
Not bad for a bunch of amateurs, eh!?