A new racer 12

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 The hardware is always a challenge . All of the hardware is custom made , usually from sand castings . The left photo is the pattern for the exhaust tips . The wooden pattern is used at the foundry to create a hollow impression in sand the shape of the desired part . Molten metal is poured into the cavity , and when the metal cools the sand is broken away leaving the casting . Hollow castings like this one also require a "core box " . The core box is used to make a block of sand ( a core ) with special indexing tabs that align the core inside the cavity in the sand formed by the pattern to eventually form the hollow inside of the finished part . It's a bit hard to explain , but the exhaust tip on the right is the end result   .

The windshield is made out of several castings , as well as extruded channel silver brazed together for the frames. I assembled it on the deck to check for fit before taking it apart and sending it out to the plater . The hatch binder was also cut out of a sheet of brass and fitted before plating . A lot of boats use strips that are butt joined , but I prefer the look of a one piece binding with no joints .


A collection of rough castings ready for chrome .

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Last modified: 04/10/05