Air Cooled 2 Stroke Cylinder Head Using Shell Casting

Not Long ago, we decided to make a custom air cooled cylinder for a two stroke engine that we're developing.

We decided to use Shell casting, mainly because we'd never done it before.

Step 1: Patterns and Sand Box

First we CNC machined some patterns and some boxes to hold the sand

Step 2: Shell Sand Mold

Heat the pattern and invert the sand over it. The sand is coated with a thermoplastic resin that binds together and forms a shell. This is used as the mold to pour the aluminum

Step 3: Make the Castings

Pour the aluminum. fettle and shotblast

Step 4: CNC Machining

Machine the Cylinder head to fit your engine

Step 5: Fit on Engine

Enjoy!!