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Blog series by Patternguy updated 02-23-2017 12:01 AM 7 parts 10833 reads 22 comments total

Part 1: A mahogany foundry pattern

02-17-2017 01:01 AM by Patternguy | 8 comments »

A picture story about building a pattern. 10 years ago, I was the CAD/CAM guy for a pattern shop. We also had a plaster molding shop and an aluminum foundry, where we pressure cast aluminum match plates. 10 years before that, I was on the bench, building the wood master patterns that went on to become match plates. 20 years before that, I was serving a Pattern maker’s apprenticeship in an iron foundry. The master I learned from once ran General Motors, “Tech Center”...

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Part 2: Making use of a layout

02-19-2017 12:48 AM by Patternguy | 0 comments »

Part 2 A quick disclaimer here…I originally thought I’d just throw the pictures up and leave it at that. However, the more I visit this site, the more I realize the level of knowledge and talent of its inhabitants is pretty dam high. I have to give the subject the attention and respect that it deserves. That’s going to take me some time. On to the story… Castings are made by pouring metal into a closed hollow mold made of sand. The hollow shape inside the mold is made by th...

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Part 3: the pieces become a sub assembly

02-19-2017 01:12 AM by Patternguy | 1 comment »

Unfortunately, I didn’t capture every step of pattern construction and have no image of a rib assembly resting on the layout. This view shows the assembled ribs with some details like fillets and radii being added to specific areas of the fingers. The side edges are left untouched at this point. Also, the only draft so far is what is on the faces matching the stops on the layout. The parting plane of the rib is defined by a line that run along the bottom of the fingers.The fingers w...

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Part 4: Rib and finger sub-assembly is finished

02-20-2017 03:21 AM by Patternguy | 6 comments »

Here are the completed rib and finger assemblies ready, for the next step.. You can see the sides of the ribs have draft and the edges have been radius-ed.Regrettably, i didn’t get any photographs of the method used to apply the draft. I am going to try illustrating it in the next entry because it is a critical operation. I also need to make an Editor’s note here: I made a mistake in describing the parting line of the ribs. Hopefully, the images will clarify the co...

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Part 5: Putting draft where it's needed

02-21-2017 02:26 AM by Patternguy | 2 comments »

Part 5 Material is removed to put draft on the rib side faces.

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Part 6: Next step: good setup ensures accurate positioning

02-22-2017 01:24 AM by Patternguy | 0 comments »

Part 6 After draft is applied and edge radii are added, the rib pieces are ready to be fit together. Spacer blocks are sanded to precise width with a draft angle that is opposite of the ribs. This type of draft is known as “back draft”. The spacers will maintain accurate dimensions between the ribs and to keep the vertical axis of each rib vertical, maintaining uniform draft on both sides. Unfortunately, I do not have an image of the next step, but I’ll ...

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Part 7: The pattern is assembled on the follow block

02-23-2017 12:01 AM by Patternguy | 5 comments »

Part 7 Assembly You cannot tell from the picture, but each rib has been pinned to the block. Pinning the ribs in position allows the spacer blocks to be removed for the next step, which is to fit pieces of material between the ribs. The material, shaped with a large radius will form the “webs” that will tie the ribs together. This illustration shows some views of the follow block with the completed pattern in position. Here is another view of the block and pattern...

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