what to do with the exterior side of bronze portholes

[Cruxandreams]

After some in-depth research, I have decided I will be casting my own bronze port rings. It is actually a quite simple process. Wow isn't the internet a wonderful resource, we can learn about anything we want with the click of a button!! Simply amazing!

Ps. I will start a new thread looking for tips and pointers on the casting process, I cant believe more people don't cast their own parts!

Check it out
Bronze Casting - YouTube

[UncleJim]

you could try emachineshop.com, download a small CAD program and layout the part and they'll cut it out for you. I haven't ordered any parts from them but use the software for other design work.

[Boasun]

The outboard side of bronze portholes? We in the commercial fleet always painted them.
The more bright work you have to polish the less time you have on other maintenance.

[LinekinBayCD]

Originally Posted by Cruxandreams

Also wondering if anyone knows a do it yourself method of makind and installing screens inside the ports, Thanks.

There is a guy on the Cape Dory owners Assoc website that makes custom screens for Spartan Ports which look very similar. Here's a link:

http://screensofschoonerbay.com/index.html

Before you cast your own you might want to check with Spartan Marine. They are located in Robinhood ME. There might be a chance they made those Alden ports you picked up. They are still making the same ports and other bronze hardware used on Cape Dorys in the 70's 80's.

Bronze and Stainless Marine Hardware, Seacocks, Portholes, Thru Hulls - Spartan Marine Hardware and Accessories

[RichH]

Originally Posted by Cruxandreams

what about forging my own? I mean it seams pretty simple. My dad has a blacksmiths forge as well as iron ladles. Build a template out of wood, then use some kind of high temperature ceramic to make the mold, heat some scrap bronze to liquid state, pour it in the mold, and then use a grinder to clean them up... is there something I'm missing?? Also the idea Chrisncate had about finding bronze sheet, I think 1/8 would be fine, as that is the thickness of the inside face, finding it is the problem, and i'm sure it wont be cheep but I only need a 1.5' by 3' piece. I just spent $800 on the ports, and I'm sure If I had some one make them for me I would be getting close to double the price.. I cant imagine some one making them for less than 100 dollars a ring.. really appreciate all your input everyone. Man these suckers are gonna look sweet when I get em in, not to mention all the nice cool draft Ill be getting with opening ports!

If you dont have long term expertise in the casting of bronze (really an 'art') you will invariably wind up with spongy/porous, full of slag-metal with lots of 'laps' and other irregularities.... and you will destroy some expensive metal in doing so.
Another poster suggested buying plate bronze and have someone water-jet, etc. cutting ... probably your 'best' option.

[SloopJonB]

Originally Posted by RichH

and you will destroy some expensive metal in doing so.

Just melt it down and try again. As long as you "sprue" the drag & cope adequately to let the mould vent and flow smoothly you should be O/K.

Worst case, you'll have some fun trying before you give up and let the pro's handle it.

Something that may help you decide whether or not to follow MY advice on "foundry" work;

Some years ago I had accumulated 8 or 10 dead car batteries. Instead of paying to dispose of them, I thought I'd bust them open and salvage the lead. I spent an afternoon smashing them open, extracting the PbO from the internal plastic grids, hosing down the remaining acid etc. etc.

Finally, I melted the scrap down in a gallon can - I got a grand total of FIVE Lbs of impure lead for my troubles.

[Cruxandreams]

Thanks everyone, I am going to give the "self casting" method a go. If I mess it up Ill melt it down and try again. And if I some how destroy the metal I'm working with It will be a small amount, and I'll know what not to do next time. My lovely girl friend and I will set out on my sailboat this coming fall, and I plan to be knowledgeable enough in most fields of boat work to pick up little jobs along the way to keep us going. If I can add casting alloys to my list of skills, I think it’s worth some effort to try to learn, even if it ends up costing me a couple hundred dollars. I consider it an investment in myself, and our future. Ill be so proud of my self when I have finally successfully made six beautiful bronze ovals to decorate the outside of my teak cabin sides, I'll want to teach everyone I meet along the way how they too can cast bronze. At this point in our lives we feel like we want to endlessly cruse the world touching different people with our knowledge, as well as learning new things from all the wonderful souls we run into along the way. So in my mind, this is just another skill I will be able to add to my list of can do's that will save me the little bit of money we have, and give me a great since of fulfillment as well. Not to mention it seams like it will be a lot of fun! Seams like a win-win to me. Thank you all for your time, and thoughts! Cheers.

[WanderingStar]

I tried some casting a few years back. Be careful, study first, have fun. There are some threads on the WoodenBoat Forum about bronze casting. My results were limited success with practice runs of scrap metal before I moved away from my kiln. Let us know how it goes.