IMPROVEMENTS IN MOULDING OR MANUFACTURING CAST-IRON PIPES, AND OTHER GENERALLY SIMILAR HOLLOW ARTICLES
Year: 1857

page_text: LETTERS PATENT to Walter McFarlane, of Glasgow, in the County of
Lanark, North Britain, Engineer, for the Invention of "IMPROVEMENTS IN
MOULDING OR MANUFACTURING CAST-IRON PIPES, AND OTHER GENERALLY
SIMILAR HOLLOW ARTICLES."
Sealed the 22nd January 1858, and dated the 23rd November 1857.
PROVISIONAL SPECIFICATION left by the said Walter McFarlane nt
the Office of the Commissioners of Patents, with his Petition, on the
23rd November 1857.
1, WALTER MCFARLANE, of Glasgow, in the County of Lanark, North
Britain, Engineer, do hereby declare the nature of the said Invention for
"IMPROVEMENTS IN MOULDING OR MANUFACTURING CAST-IRON PIPES, AND OTHER
GENERALLY SIMILAR HOLLOW ARTICLES," to be as follows, that is to say :-
This Invention relates, more or less, to variations and improveuients upon
Mr. Walter McFarlane's Invention of "Improvements in Moulding or.
Manufacturing Cast-iron Pipes," for which he has already obtained a grant
of British Letters Patent, bearing date on or about the 26th day of February
1857, and it consists of various mechanical arrangements, contrivances, and
means for moulding and manufacturing cast-iron pipes, ducts, columns, and
other hollow or tubular articles in a more accurate, efficient, and economical:
manner than has hitherto been the practice. One part of the Invention refers
to the moulding and manufacturing of the faucet part of pipes or hollow cylin-

page_text: ders vertically by means of mechanism. The outside and core of the pipe are
formed in the manner described in the Specification of the Patent of 26th
February 1857. The plain cylindrical portion of the outside mould is con-
tinued up as high as the upper end of the faucet; said portion of the mould to
the extent of the faucet is then acted upon by a tool, which may be called a
template knife sleeker tool, which removes the superfluous portion of the sand,
and at the same time forms and finishes the pipe faucet in the outside mould.
In like manner the corresponding part of the core of the faucet is made
separate by placing a block of sand on a board or plate, which is made to
revolve vertically, and a template knife sleeker tool of the required shapo
being brought into contact with it, the faucet part of the core is formed and
finished of sand, which is turned by a lathe in a horizontal position, and
acted upon by
a tool, as already described; it is then placed into the mould,
and the cover is complete.
Another part of the improvement and Invention is to executo the moulding
or manufacturing of pipes and hollow articles of square, rectangular, trefoil,
or other transverse section of a similar kind horizontally by the use of patterns
parted longitudinally in two or more pieces, such patterns answering or
fulfilling the double purpose of forming the mould for the outside of the pipe
or article; and also in like manner the inside forming the core.
Another part of the Invention is a mode of facilitating the making the cores
for articles of a circular, trefoil, or other shape. By this mode, after the outside
mould of the under half of the pattern is formed with its laying down board, is
turned over, and thus exposes the interior of the under half of the core pattern.
The inside of this under half of pattern is filled with core sand rainmed or com-
pressed, and core sand is also laid at the top of said under half, equal to tho
size of the upper half of the required core, and which is also rammed or
compressed. A tool, already described as a "template knife sleeker," of the
exact shape of the upper part of the required core, is then guided along the
edge of the pattern, and cuts off and removes the superfluous sand, and thus
shapes and prepares the upper part of the core for receiving its corresponding
part of pattern.
Another part of the Invention is to provide by mechanical arrangements in
the core and outside mould for the core box kept in the centre of the mould.
This is effected by a vertical bearing stud or studs hinged, being attached to
the coro bars, having one arm projecting upwards and another projecting
downwards. In the end of the upper arm of the stud there is a socket for
holding the "thickness peg," described in the Specification of the Patent of
26th February 1857, the upper end of which comes into contact with aud.

page_text: rests against the bearing stud in the upper half of the outside mould, the other
or lower arm of core bar bearing plate projects downwards and comes into
contact with the end of a "thickness peg," which rests in a socket in a bearing
stud in the under half of the outside mould. The core being thus suspended..
and kept in its proper position is not affected by the action of the molten
metal. Further, the "thickness pegs" may be improved by being made
irregular in the diameter, or indented throughout, or only partially, for the
purpose of being firmly retained in the casting.
Another portion of my Invention is the formation and use of core bars,
hinged either at one or more places for casting bent, angular, or irregular
shaped pipes and fittings. Such core bars are binged at one or more places,
so as to allow and enable them to be removed from the finished casting with-
out requiring them to be broken into pieces.
Another portion of the Invention relates to the making of "gates" in.
moulds for pipes and similar castings. The gate is of the usual oblong wedge
shape, but the gate pattern is fitted on its sharp edge with one or more
projecting pegs or other guides, corresponding holes being made in that part
of the pattern of the article to be cast which is adjacent to the gate, into which
holes the said pegs enter, and thus the gate is put in its proper place when the
upper half of the mould is being rammed up.
It is remarked generally that various classes of tubular or hollow articles,
in addition to those herein-before particularly mentioned may be most
effectively moulded and manufactured by means of the Invention and improve-
ments, the nature of which are before mentioned.
SPECIFICATION in pursuance of the conditions of the Letters Patent, filed.
by the said Walter McFarlane in the Great Seal Patent Office on the
20th May 1858.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, WALTER
MCFARLANE, of Glasgow, in the County of Lanark, North Britain, Engineer,
send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her Letters,
Patent, bearing date the Twenty-third day of November, in the year of our
Lord One thousand eight hundred and fifty-seven, in the twenty-first year of
Her reign, did, for Herself, Her heirs and successors, give and grant unto me,
the said Walter McFarlane, Her special license that I, the said Walter
McFarlane, my executors, administrators, and assigns, or such others as I, the

page_text: said Walter McFarlane, my executors, administrators, or assigns, should at
any time agree with, and no others, from time to time and at all times there-
after during the term therein expressed, should and lawfully might make, use,
exercise, and vend, within the United Kingdom of Great Britain and Ireland,
the Channel Islands, and Isle of Man, an Invention for "IMPROVEMENTS IN
MOULDING OR MANUFACTURING CAST-IRON PIPES, AND OTHER GENERALLY SIMILAR
HOLLOW ARTICLES," upon the condition (amongst others) that I, the said
Walter McFarlane, by an instrument in writing under my hand and seal,
should particularly describe and ascertain the nature of the said Invention,
and in what manner the same was to be performed, and cause the same to
be filed in the Great Seal Patent Office within six calendar months next
and immediately after the date of the said Letters Patent.
NOW KNOW YE, that I, the said Walter McFarlane, do hereby declare
the nature of my said Invention, and in what manner the same is to be
performed, to be particularly described and ascertained in and by the
following statement in writing, referenco being had to the accompanying
Drawings and to the letters and figures marked thereon, that is to say:-
My said Invention relates more or less to variations and improvements upon
an Invention of "Improvements in Moulding or Manufacturing Cast-iron
Pipes, for which I have already obtained a grant of British Letters Patent,
bearing date on or about the Twenty-sixth day of February, One thousand
eight hundred and fifty-seven, and it consists of various mechanical arrange-
ments, contrivances, and means for moulding and manufacturing cast-iron
pipes, ducts, columns, and other 'hollow or tubular articles in a more accurate,
efficient, and economical manner than has hitherto been practised. One part
of the Invention refers to the moulding and manufacturing of the faucet part
of pipes or hollow cylinders vertically by means of mechanism. The outside
and core of the pipe are formed in the manner described in the Specification
of the Patent of Twenty-sixth February, One thousand eight hundred and
fifty-seven.
The plain cylindrical portion of the outside mould is continued up as high
as the upper end of the faucet, and the said portion of the mould to the extent
of the faucet is then acted upon by a tool, which may be called and is herein
designated as a template knife sleeker tool," which removes the superfluous
portion of the sand, and at the same timo forms and finishes the pipe fauret
in the outside mould. In like manner the corresponding part of the core of
the faucet is made separately by placing a block of sand on a board or plate,
which is made to revolvo vertically, and a template knife sleeker tool of the
required shape being brought into contact with it, the faucet part of the core

page_text: is formed and finished of sand, which is turned by a lathe in a horizontal
position and acted upon by a tool, as already described; it is then placed into
the mould and the core is complete.
Another part of the improvements and Invention is to execute the moulding
or manufacturing of pipes and hollow articles of square, rectangular, trefoil, or
other transverse section of a similar kind horizontally, by the use of patterns
parted longitudinally in two or more pieces, such patterns answering or
fulfilling the double purpose of forming the mould for the outside of the pipe
or article, and also in like manner the inside forming the core.
Another part of the Invention is a mode of facilitating the making the cores
for articles of a circular, trefoil, or other shape. By this mode, after the
outside mould of the under half of the pattern is formed, this with its laying
down board is turned over, and thus exposes the interior of the under half of
the core pattern. The inside of this under half of the pattern is filled with
core sand rammed or compressed, and core sand is also laid at the top of the
said under half equal to the size of the upper half of the required core, and
which is also rammed or compressed. A tool already described as a "template
knife sleeker," of the exact shape of the upper part of the required core, is
then guided along the edge of the pattern, and cuts off and removes the
superfluous sand, and thus shapes and prepares the upper part of the core for
receiving its corresponding part of the pattern.
Another part of the Invention is to provide by mechanical arrangements in
the core and outside mould for the core being kept in the centre of the
mould. This is effected by a vertical bearing stud or studs hinged, being
attached to the core bars, having one arm projecting upwards and another pro-
jecting downwards. In the end of the upper arm of the stud there is a
socket for holding the "thickness peg," described in the Specification of the
Patent of the Twenty-sixth February, One thousand eight hundred and fifty-
seven, the upper end of which peg comes into contact with and rests against
the bearing stud in the upper half of the outside mould; the other or lower
arm of the core bar bearing stud projects downwards, and comes into contact
with the end of a "thickness peg," which rests in a socket in a bearing stud
in the under half of the outside mould. The core being thus. suspended and
kept in its proper position, is not affected by the action of the molten metal.
Further, the "thickness pegs" may be improved by being made irregular
in the diameter or indented throughout or only partially for the purpose of
being firmly retained in the casting.
Another portion of my Invention is the formation and use of core bars
hinged either at one or more places for casting bent, angular, or irregular

page_text: shaped pipes and fittings. Such core bars are hinged at one or more places,
so as to allow and enable then to be removed from the finished casting with-
out requiring them to be broken into pieces."
Another portion of the Invention relates to the making of "gates" in
moulds for pipes and similar castings. The gate is of the usual oblong wedge
shape, but the gate pattern is fitted on its sharp edge with one or more
projecting pegs or other guides; corresponding holes being made in that part
of the pattern of the article to be cast, which is adjacent to the gate into
which holes the said pegs enter, and thus the gato is put in its proper place
when the upper half of the mould is being rammed up.
It is remarked generally that various classes of tubular or hollow articles, in
addition to those herein-before particularly mentioned, may be most effectively
moulded and manufactured by means of the Invention and improvements, the
nature of which are herein-before mentioned. And in order that my said
Invention may be properly understood, I shall now proceed to describe the
several illustrative Figures on the explanatory Sheets of [Drawings which I
have hereunto appended for the purpose of showing certain modifications
under which my improvements may be judiciously carried out in practice. In
the Specification of the British Letters Patent granted to me for "Improve-
ments in Moulding or Manufacturing Cast-iron Pipes," and bearing date on
or about the Twenty-sixth day of February, One thousand eight hundred and
fifty-seven, there is described a mode of forming the moulds and cores of pipes
intended to be "cast on end," or in a vertical position.
Now, the first part of my present Invention consists of an improved system
or mode of forming the moulds and cores of the faucet portion of such pipes.
In the Specification referred to, the plain cylindrical part of the pipe is
described as being made by means of a pattern, which serves the twofold
purpose of forming the mould and the core simultaneously; the faucet part
of the mould and its core being formed by means of patterns in the ordinary
manner. In lieu of this modo I prefer to form the faucet part of the mould
and its core with the aid or by means of peculiar moulding tools, which I
designate template knife sleeker tools. I so designate theso tools becauso
they serve the triplicate purposes of a moulding knife for cutting away the
superfluous sand of a "template," by means of which the sand is moulded or
fashioned to the required contour or outline, and of a "sleeker," by which a
smooth and even surface is given to the sand. These template knifo slocker
tools in their various modifications are capable of being very extensively
employed in the preparation of moulds and cores for casting; and the process
or art of moulding is thereby greatly simplified.

page_text: Figure 1 on Sheet 1 of the annexed Drawings is a vertical section of the
upper part of a mould-making machine, corresponding to one of the arrange-
ments shown in the Drawings of the Specification herein-before referred to,
but having my improved mode of forming the faucet part of the pipe applied
thereto; Figure 2 is a plan corresponding to Figure 1; Figure 3 is an eleva-
tion, showing the mode of forming the core; and Figure 4 is a plan corre-
sponding. The funnel-mouthed moulding box A and the core bar B are the
same as described in the Specification herein-before referred to. The cylin-
drical space which constitutes the pipe mould is formed by means of a rotatory
pattern, as therein described. This cylindrical space is indicated by the
parallel lines C, and in moulding pipes upon this system the pattern is carried
right up to the top of the moulding box A. The faucet portion of the mould
is now formed by means of the modification of the template knife slecker
tool, which is specially adapted for the forming the faucet part of pipe moulds,
the casting of which is to be effected "on end" or in the vertical position.
In this instance the template knife sleeker tool D consists of a strip or narrow
segment of cast iron or other suitable metal, which is curved in such manner
that its face corresponds to the contour of the part to be moulded; thus, the
face of the templáte knife slecker is of a convex form. The face of the tool
is made quite smooth, and the front edge, or that part which is foremost when
the tool is put in motion, is bevilled off to form a knife-like edge, as shown at
E, in the plan, Figure 2, on Sheet 1 of my Drawings. The template knife
sleeker tool is cast or made with a rib F at the back of the working face;
which connects it to the tubular socket G. This socket has fitted thereto a
spindle II, that fits the tubular aperture in the core bar B. Rotatory motion
is imparted to the template knife slecker tool either by hand or by means of
machinery, and as the tool is traversed round, the knife edge E cuts away the
superfluous sand, whilst its template shape serves to mould and compress the
sand to the required figure, and its smooth polished surface sleeks and finishes
the faucet mould at one operation. The upper edge of the template knifo
sleeker tool. is curved over at I, and rests upon a ring J, which is placed
inside the mouth of the moulding box A. This ring serves as a guide to the
tool during its rotatory traverse. I may bere observe that I do not limit
myself to this particular arrangement of the parts, nor to the precise modus
operandi, as the formation of faucet moulds, by means of template knife
sleeker tools, may be greatly varied in the details. In order to form the core
for the faucet mould, a board or metal plate K, Figures 3 and 4, is used;
this has in its centre a vertical. spindle L, which is made to fit the tubular
aperture in the core bar B. A block of sand is placed upon the board or

page_text: plate K, and the socket M of the template knife sleeker tool N is slipped
over the spindle L. The template knife sleeker tool N for the core is similar
in its construction to the tool used for the faucet mould, excepting that its
working face is concave, and corresponds in its outline to the convexly curved
figure intended to be given to the core. The core template knife sleeker tool,
by means of its radial rib or connecting piece, thus extends over the unmoulded
mass of sand; the tool is made to travel round the mass, and the compound
tool cuts, shapes, and sleeks it to the desired and predetermined form, as
shown in Figure, 3 of my Drawings. I may hero direct attention to an
important feature in the construction of the template.knife sleeker tools. In
forming the, cutting edge, the metal is bevilled away from the template or
sleeking face of the tool, and the cutting part is formed upon the back edge
as it were of the metal. In some cases, however, it may be found better to
reverse the cutting edge, and have it on the inner edge as it were of the
metal. The effect of this is, that the template knife edge cuts the sand to
the required shape, but as much larger as the cutting edge is removed from
the sleeking surface; the sand is, however, compressed to the true size by the
sleeking face of the template. This compression of the sand renders tho
moulded surface much more compact and perfect than can be obtained in the
ordinary manner.
I will now describe my system of moulding cast-iron pipes or other hollow
articles by means of patterns parted in two halves longitudinally; and also
the mode of preparing cores for such moulds, by means of the inside of the
said patterns and hand or machine worked template knife sleeker tools, the
said moulds and cores being arranged and prepared for moulding in a hori-
zontal position.
Figure 5 on Sheet 1 of my Drawings is a plan showing the upper half of
a moulding box, with the half pattern in its place upon the laying down
board; Figure 6 is a transverse section of the same. Both of these Figures
have my improvements in forming the "gates" of moulds applied thereto.
Figuro 7 is a plan of a core templato frame, and hand template knife sleeker
tool, arranged for forming solid cores; Figure 8 is a plan of the core template
frame; Figure 9 is an, enlarged view of the template knife sleeker tool, as
adapted for forming solid cores.
Figure 10 is a side view of one. modification of my improved core bar;
Figure 11 is a transverse section of the same, and Figure 12 is a plan
howing the template frame applied to the formation of "elbows," "bends,"
and other hollow articles of, an irregular figure. In preparing the moulds for
pipes the half pattern O is a counterpart of one half of tho intended pipe

page_text: divided by a line passing longitudinally through it. This half pattern is
placed upon the laying-down board P, and retained in its proper position by
means of core prints or other catches or fastenings. If it is the upper half
of the mould that is being made; the top part of the mould pattern with it's
concave side downwards is laid on the laying-down board, and the gate
patterns are secured to the mould pattern, and then the moulding box Q is
laid on.
In Figures 13, 14, and 15 are shown two forms of my improved "gate"
patterns; Figures 13 and 14 are an end view and longitudinal vertical section
of a rectangularly shaped gate pattern, and Figure 15 is an elevation of a
conically shaped gate pattern. These gate patterns R are made hollow, and
they have passed through them one or more wires or slender metal rods S.
The lower end of each wire is at right angles or formed into a T piece or peg
key, the upper extremity of the wire is turned into a ring to enable the
moulder to turn it easily round. These wires or "swivel peg keys" S serve
to fasten the gate patterns to the mould pattern O; the T end of each swivel
peg key passes through a slot made for the purpose in the pattern; the swivel
peg key is turned half round, so that the T end lies across the slot. This
arrangement of the gate patterns, by which they are locked as it were to the
mould pattern, is of great convenience to the moulder, as it prevents the gate
pattern from shifting or being pressed upwards or away from its proper
position on the pattern during the operation of ramming up the top part of
the mould. I prefer to make these improved gate patterns of hollow iron, as
I have found in practice that more perfect castings are produced thereby, but
I do not restrict myself to the use of this material for the said purpose.
These improved gate patterns may be used with advantage in the preparation
of moulds for casting pipes, ducts, gutters, columns, and other hollow articles;
and are also applicable to the various fittings of such castings. The lower
half of the pattern is first put on the laying-down board, and the drag part of
the moulding box is then put on and rammed up with sand. The box with
its laying-down board is turned over and the laying-down board is then
removed; the inside of the pattern is partly filled with sand, and the core bar
with peg stud set in its proper position and partially covered with sand. The
top half-mould pattern being laid on the laying-down board, and the gate
patterns fastened in their respective places, as shown in Figure 5 on Sheet 1
of my Drawings, the moulder proceeds to ram up the half mould, as before
described, in reference to the drag or bottom half of the mould. My system
or mode of preparing the cores for the daplex moulds differs materially from
my ordinary practice. In place of forming the core in two halves, and

page_text: pressing the two parts together to complete the core, I form the entire core
at one operation, so that a solid and perfectly compact mass of sand is
obtained. The cores. thus made aro much superior to those of the ordinary
kind, inasmuch as the molten metal has not the same tendency to press into
and split or break the core at any part, since they are of uniform solidity
throughout.
Figure 7 on Sheet 1 of my Drawings is a plan showing the drag part of
the moulding box and half pattern, and the operation of forming a core
therein. The internal part of the pattern T is semicircular in figure; this is
partially filled up with sand; a core bar U is placed upon the sand, and on
this the mandril V; the sand is then partially filled in; a "template W
is then put on the mould and kept in position by the pins X, which pass
through the snugs on the box. The template framo W is a rectangular
frame of iron with a snug on each side of it; the open internal part of this
frame at each end is made to correspond exactly to the contour of the core
to be made, as is shown in the separate plan of the frame, Figure 8 on
Sheet 1 of my Drawings. The open or body part of the template frame is
mado a little larger than the core to allow for the thickness of the coro
template knife sleeker tool passing up and down the inner sides of the
template frame, and also for placing on the end pieces for ramming up tho
ends of the core. A quantity of the moulding sand, more than enough to
form the core, is heaped up in the opening of the template frame W, and this
sand is moulder to the figure of the upper portion of the core by the template
knife sleeker tool.
A separate end view of one modification of the band template knife stecker
tool is shown in Figure 9 on Sheet 1 of my Drawings. In this modification
the tool consists of a semicircular plate of metal, the concave surface of which
forms the template and sleeking surfaces; the curved edge at the front part
is bevilled off, and forms a knife to cut away the sand to the predetermined
size and shape. A vertical guard is placed at the back of the tool which
extends over the back or convex part of the tool; this guard serves to carry
the superfluous sand to the sides and provent its falling upon the finished
part of the core or mould. Other modifications of the hand template kuile
slecker tools are shown in Sheet 2 of my Drawings.
Figures 9 and 10 on Sheet 2 represent an end view and plan of a template
knife sleeker tool, adapted for cutting, shaping, and sleeking the upper part
of a core of a trefoil figure in its cross section; Figures 11 and 12 are an end
view and under side view of a template knife sleeker tool, of a semicircular
figure. In these Figures, the concave surfaces which form the template and

page_text: slecking portion of the tools extend from P to Q, the bevilled part which forms
the template knife is shown at R. In both these modifications of the tem-
plate knife sleeker tools their lateral edges are extended downwards at S,
where they overlap the half patterns T; this mode of guiding the tools may,
however, be modified according to circumstances. The tools may also be so
modified in their construction according to the particular use to which they
are to be applied, that in some cases the tool may form a template knife only,
and under another modification a template sleeker only. The tools may also
bo actuated either by hand or machinery, according to the class of work they
are applied to. As the template knife sleeker tool is pushed along the sand, it
is guided accurately in its course by the inner sides of the opening in the teni-
plate frame, so that the operator cannot possibly err in forming the core truly
cylindrical. The ends of the core are completed by putting on the end pieces,
and the sand is now rammed in at each end, which completes the moulding
operation and secures the production of an accurately homogeneous core.
These moulding operations, although described as being performed whilst the
moulding boxes are in a horizontal position, are equally application to the pre-
paration and formation of moulds either in a diagonal or vertical position, as
may be found most suitable to the class of work. When the foregoing kind
of core is to be used in moulds to be cast on end, there is placed on the bottom
end of the core bar a projection that corresponds to and fits into a socket in
the lower end of the moulding box; the top end in like manner fits into its sand
bearing in the outside mould, and thus the core with its outside mould are
kept in their proper positions. In this case no peg stud and socket nor pegs
or nails are required.
Figure 11 on Sheet 1 of my Drawings shows the application of the tem-
plate frame in forming the cores for moulds of "elbows," "bends," and other
irregularly shaped castings. In this modification the template frame sur-
rounds the pattern, the use of and the purpose it serves being somewhat the
same as before described in reference to Figures 6 and 7 on Sheet 1 of my
Drawings. Figure 10 is a side view, and Figure 11 is an end view of one of
my improved core bars; the upper face of the core bar has a longitudinal
groove or recess formed in it, with cross straps across the top to prevent the
vent mandril splitting it in the drawing of it out. This groove is intended to
receive the mandril V, Figure 7; the laterally projecting stud in the core bar
forms a socket for the "thickness peg" in lieu of using a core strap. In some
cases pegs may be dispensed with, as, for instance, when a sufficiently rigid
core bar can be applied. This system of moulding by means of duplex pat-
terns partially forming moulds and cores is applicable to the preparation of

page_text: moulds and cores for casting articles, the transverse section of which may be
square, rectangular, trefoil, or other polygonal or irregular figure..
In Figures 7 and 8 on Sheet 2 of my Drawings is shown a plan and trans-
verse section of a mould, partially prepared for a rectangularly shaped casting.
In this modification the template knife sleeker tool for moulding the upper
half of the solid core is of an angular figure, as shown in the end view of the
tool, Figure 8. The modus operandi of preparing the half pattern and sub-
sequently the mould and core for the complete casting is similar to that herein-
before described.
In Figures 15, 16, and 17, on Sheet 2 of my Drawings, is shown my
improved inode of forming cores only, and unconnected with the pattern or
the outer mould. Figure 15 is a plan of the improved core box with the tem-
plate frame or guide attached, and the core template knife sleeker tool shown
in position, one part of the sand being moulded by the operation of the tool,
and the other part being in the rough unmoulded state. The lower half of
the core box U is of the usual form; the template knife sleeker tool V has a
vertical guard W at the back, but may be similar to any of the various modi-
fications herein-before described. In preparing a core with this core box the
lower half of the box is partially filled with sand, and a core bar X is imbedded
therein with its bearing stud projecting upwards. A little more sand is put in
upon the core bar, and the vent mandrils Y are laid in; a sufficient quantity
of sand is now added to complete the core. The template frame Z serves to
guide the template knife sleeker tool. The moulding tool V is rested upon
the template frame and guided along the inner sides of the frame and the
edges of the core box, thus sleeking and finishing a portion of the core, more
or less, as may be found convenient. At each extremity of the core box U is
hinged a short cylindrical part a, and when the main or body portion of the
core is finished by the template knife sleeker tool, the end pieces a are turned
over upon the core, as shown in Figure 15, and the ends of the core are then
rammed up from each end. The operator then turns back the end pieces a;
the core is lifted out, and the "thickness peg" is put into its socket in my
ordinary way; in this manner a perfectly uniform and accurately homogeneous
core is produced, in every respect the same as when made in combination with
the outside mould herein-before described.
In Figures 16 and 17, the cylindrical end pieces a are shown closed to 'rani
up the ends, and thrown back to mould the core or lift it out of the core box.
The finished core is placed in the lower half of the mould, the top half of the
pattern aml moulding box put on, as shown in Figure 13; the top half is
then rammed up, taken off, and the half pattern removed; it is then replaced,

page_text: and is ready for casting. Figure 14 shows the casting complete; the position
of the "gate" for pouring in the molten metal is indicated dotted lines at
the upper part of the Figure.
In the foregoing modification the making of the cores is described as being
effected by hand, but in large work the filling and ramming up of the sand
may be effected by machinery, as also the actuating of the template knife
sleeker tools. Various modifications of the details of this system of core
making, wherein the mass of sand is uniformly compact throughout, and not
formed, as is usually the case, in two separate halves, joined by compression,
may be advantageously adopted.
Figure 18 represents some modifications of improvements in the shape of
the "thickness pegs." Instead of making these pegs of a uniform cylindrical
figure, I prefer to make their peripheries irregular, or indented or notched
as shown in the Figures. By this means the pegs are more firmly retained
in the casting than hitherto, and they may be riveted into or more firmly
compressed into the metal, with a view of preventing any leak or defect at
that part of the finished casting.
Figure 19 represents a side view and plan of an improved core bar, the
object of the improvement being to keep the core bar exactly in its proper
position in the mould. This is effected by means of one or more hinged
bearing studs, the extremities of which project on either side of the core
bar. In some cases the studs may be fixed to the bar, and may be made to
project only upon one side of the bar. As the core bar is arranged in
Figure 19, the hinged bearing stud b comes in contact with and rests against
the bearing stud in the upper half of the outside mould box, whilst the lower
extremity of the bearing stud comes in contact with the end of a thickness
peg, which rests in the socket of a bearing stud in the under half of the
outside mould box, and thus serves to keep the core exactly equidistant in the
mould during the operation of casting.
Another of my improvements consists in making the curved core bars used
in forming the cores of moulds for casting bent, angular, or irregularly shaped
pipes and fittings in two or more parts, and binging the parts together at one
side. Such an arrangement of a curved core bar is shown in Figures 20
and 21 on Sheet 2 of my Drawings, Figure 20 being a plan of the core bar,
and Figure 21 an edge view of the same. In this modification the core bar
is made in two parts c and d, and these pieces are hinged together at e, the
free extremities of the bar being connected together by a cottar f. These
core bars may be modified in their construction, and made in more than two
parts, the several pieces being hinged together, as shown at e, and the free

page_text: ends secured by a cottar. This arrangement of the core bars in jointed parts
admits of their being withdrawn from the finished casting without necessitating
their being broken in pieces, or otherwise treated as heretofore.
Figures 1 to 6 on Sheet 2 of my Drawings represent my improved system
of preparing moulds and cores for casting hollow articles, such moulds and
cores being made without the aid of patterns, and solely by the agency of
suitable template knife slecker tools.
A
Figure 1 is a plan, and Figure 2 a transverse vertical section, of a moulding
box, with the core formed by means of the template knife sleeker tool, which
is also shown in plan and end view. The "drag" or lower part of the moulding
box A is first laid down and filled with sand rammed and compressed; a pair
of guide bars B, or a "template frame," may be used in lieu thereof. The
guide bars B are laid parallel to the sides of the "drag," and imbedded in the
sand, the upper face of each bar is made flush with the edge of the box.
quantity of core sand is then laid along the centre of the moulding box; the
quantity of sand thus added should be rather more than enough to form the
required core. This sand is moulded to a semicircular shape by means of a
core template knife sleeker tool, the operating face of which is shaped to the
exact size of the core. The central part C of the tool is semicircular, and
from the lower edges the cutting and sleeking surface is extended laterally
at D; and in this modification the lateral edges are bent downwards, as
shown at E. These edges serve to keep the tool in its proper place upon the
guide bars B. The tool is placed upon one extremity of the bars 13, and
moved along to the other end. In its course the core template knife sleeker
tool cuts away the superfluous sand, which is thrown off by means of the
diverging diagonal wings or fins F, which spring from the front part of tho
semicircular portion C, and extend backwards in a diagonal direction over
the horizontal lateral parts D. The wings F guide off the superfluous sand.
and prevent it from falling upon the moulded part. The operator guides the
tool along by the horizontal handle G, nothing more being required than to
merely move the tool from one end of the "drag" to the other. The hangers
are then put into the guide rods, and a little parting sand or paper is then
put upon the imoulded surface, and the top part. II of the moulding box is put
upon its corresponding lower half. Sand is then filled in, and the box is
rammed up in the usual manner, care being taken to avoid ramming the sand
so as to injure the moulded core. The upper half of the box is now parted or
lifted off from the under or drag part, and the bangers carry along with
them in the upper half of the box the guide rods or template, as the case may
be, their under sides being now exposed. The sand in the top part of the
T

page_text: moulding box is moulded to a concave form, corresponding to the core formed
in the drag A. The concave surface of the mould is enlarged to the size of.
the exterior of the pipe by means of a mould template knife sleeker tool, as
shown in Figures 3 and 4 on Sheet 2 of my Drawings. The mould template.
knife sleeker tool I is similar in construction and operation to the core
template knife sleeker tool herein-before described, excepting that its shaping
and sleeking surface is made convex, and larger than the core-shaping tool,
by the thickness of the metal of the duct to be cast. The upper part of the
circular portion at J is made horizontal, which cuts the sand to a uniform
level, so that the two parts of the complete mould are joined accurately at a
central line. The laterally projecting portions K of the tool are made to fit,
the guide bars B, by which it is guided truly along the sand. In Figure 3
on Sheet 2 of my Drawings the mould template knife sleeker tool I is shown
as having partly formed the half mould. In the lower part of the Figure the.
sand is represented as cut out to a large diameter than the core in Figure 1
of the same Sheet. The drag and top part of the moulding box are now
put together, and from this mould a gutter, duct, or pattern in metal may
be cast..
With these several improvements in the preparation of moulds and cores
for casting, the art of moulding is greatly simplified, labour and materials are
economised, and the castings produced are superior in point of workmanship
and commercial value.
Having now described and particularly ascertained the nature of my said
Invention, and the manner in which the same is or may be used or carried
into effect, I may observe, in conclusion, that I do not confine or restrict
myself to the precise details or arrangements which I have had occasion
to describe or refer to, as many variations may be made therefrom without
deviating from the principles or main features of my Invention; but what I
consider to be novel and original, and therefore claim as the Invention
secured to me by the herein-before in part recited Letters Patent, is,-
First, the manufacture or production of the faucet parts of pipes or hollow
articles, both for the outside mould and inside cores of vertical moulds and
castings, by the agency of "template knife sleeker tools," and apparatus
connected therewith, as herein-before described.
Second, the system or mode of moulding and manufacturing cast-iron pipes
and hollow articles of a cylindrical, rectangular, trefoil, or other irregular
figure in their transverse section, in a horizontal position, in which the pattern
of the pipe serves the twofold purpose of forming the moulds and partially

page_text: forming the cores, being assisted in the latter operation by "template knife
sleeker tools," as herein-before described.
Third, the system or mode of making cores for cast-iron pipes and similar
articles of one uniform inass of sand throughont, by the aid of core box and
"template knife sleeker tool," the latter both in its combined state, and also
as a template knife only and sleeker only, and the action of which is directed
by bearing guides, as herein-before described.
Fourth, the application and use of a "template knife sleeker tool in the
formation of said moulds and cores for ducts, pipes, and other hollow articles.
both in its combined state, and also as a template knife only and sleeker only,
and the action of which is directed by a template frame, or the bearing guides
used in horizontal moulding, as herein-before described.
Fifth, the construction of gates by means of patterns, having a swivel key
or keys attached, so that the gate pattern may be readily fixed to and detached
from the pattern, as herein-before described.
Sixth, the application and use of core bars, either grooved or plain, with a
jeg socket, stud or studs, cither hinged or fixed to the core bars used in
forming cores for pipes and other hollow articles, as herein-before described.
Seventh, the application and use of "thickness pegs" of indented, raised,
or irregular surfaces, as herein-before described.
Eighth, the system or mode of jointing or hinging the parts of curved or
irregularly figured core bars, so that the same may be readily withdrawn from
the finished castings, as herein-before described.
Ninth, the system or mode of forming the moulds and cores for ducts and
other hollow articles, by means of template knife sleeker tools, instead of
patterns, as herein-before described.
In witness whereof, 1, the said Walter McFarlane, have hereunto set
my hand and seal, this Eighteenth day of May, One thousand eight
hundred and fifty-eight.
WALTER MCFARLANE. (L.S.)