Well... at the risk of this taking forever I'm going to leave this here as a WIP. This is a project I've always wanted to do and the opportunity recently presented itself! This will most likely be cast out of a 10XX steel and will be hardfaced. If I'm lucky I might be able to mix up some 4340 or something similar... anyway, pattern making first, casting later.
Well lets get started.
Design, poorly dimensioned but you get the general idea.
I had a sketch in one of my books that I added some measurements and ended up with this design. Now there have been a few design changes since this was drawn up, but the drawing as above is estimated at 156lbs. With a 300lbs total melt capacity I'm at my limit, assuming about a 50% yield on this casting. More on that side of the process when we get there..
Raw pattern materials: 4'X8'X0.75" MDF and 2'X4'X0.5" MDF = About 40$
The 0.75 will be used for the match plate and for the bulk of the pattern while the 0.5 will be used for templates and the middle of the pattern
The boards are cut up into four 0.75"X10"X18" and three 0.5"X10"X18" blanks. One of the 0.5 blanks is used to make a template where the rest are used to make the main body of the pattern. The main body is six layers, two of the 0.75, two of the 0.5, and then the last two 0.75. If my math is correct then that results in a 4" thick anvil with a parting line right down the center. You can see the layers in the photo below.
Now the feet are cut from the template to make new templates to add some width to the base of this anvil.
Now all the parts are cut out, with the exception of the gating, core prints, locators and riser locator I'm ready for the next step, truing up the profile and adding draft. Sadly I don't have access to a good disk sander so I had to stop here for the day.
More to come!
PS. Further installments will have more photos, my cell phone did a terrible job today.