Hern ironworks Verbruggen Barrel - Graybeard Outdoors
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post #1 of 62 (permalink) Old 02-17-2019, 09:05 AM Thread Starter
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Default Hern ironworks Verbruggen Barrel

Jack Hern and I have decided to partner in the making of a Hern Verbruggen barrel.
My part is to attempt to make the wooden model in two equal halves to use as a positive in Jack's molding process.


There are a lot of pictures to share.


Here are some of the processes Jack uses in his foundry. They are of several different barrel types but you will get an idea of how it works.
These show different wooden forms, how they are set, how the liner is placed, and some finished models.



These are Jack's pictures.













































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post #2 of 62 (permalink) Old 02-17-2019, 09:32 AM
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Thank you, sir, for the post.
What a process!

Think twice, shoot once...
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post #3 of 62 (permalink) Old 02-17-2019, 10:34 AM Thread Starter
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Here is the next series of pictures.
The making of a Verbruggen barrel in two halves.


The two halves have no glue between them. There are three 1" alignment pegs.

I then countersunk 5 holes and set 3" deck screws deep in the wood to hold the halves together.
I also glued end caps on the ends. One side allowed me to grab it with a four jaw chuck.

The other side provided some stability.


This is the biggest thing I ever had on my lathe. 44.5" long and 53 lbs.



I started the lathe out at 350 RPM and it almost beat me to death before I could get it rounded enough to move to 750 RPM's.


Later, I increased the speed to 1200 RPM's for a smoother finish.

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post #4 of 62 (permalink) Old 02-17-2019, 10:58 AM
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Thanks for sharing this Micheal. I really had no idea how they did this casting of barrels. Interesting for sure.


Is that some sort of sand they cast in?



Nice Lathe work also.
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post #5 of 62 (permalink) Old 02-17-2019, 11:30 AM Thread Starter
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Quote:
Originally Posted by carbineone1964 View Post
Thanks for sharing this Micheal. I really had no idea how they did this casting of barrels. Interesting for sure.


Is that some sort of sand they cast in?



Nice Lathe work also.

Thanks Bruce,

Yes, that is casting sand.
At this point the barrel is just roughed out.
The next set of pictures will show it being fine tuned.
Almost everything still needs to be taken down about 1/8" or so before final sanding.
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post #6 of 62 (permalink) Old 02-17-2019, 11:40 AM Thread Starter
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Before fine tuning, I noticed that the seam was opening a little. Hose clamps solved the issue nicely. I just moved them whenever I had to.
They also allowed me to pull the 3" deck screws and fill the 3/8" holes with a short dowel.


I got stage one finished. I'm happy.
It worked out and both halves are flat.

Now I have to figure out the trunnion issue. They will be 2 1/4" diameter, but they will be mounted below center line as opposed to centered in the barrel. I have to work that out.
They will be poured in the vertical position so they each have to have a 1 degree taper to allow the casting sand to release them without collapsing the sand.
That part is easy. The below center line boring of a 2 1/4" hole is harder.
I'm thinking on it.
Enjoy the pics.

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post #7 of 62 (permalink) Old 02-17-2019, 11:57 AM
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I see now. I was going to ask a dumb question how you split the barrel in half and it was still full dimensions. I must have missed it is made in two separate pieces originally. That makes sense now. My feeble mind was thinking you cut it down the middle after the lathe work, sorry kinda slow to catch on today,LOL
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post #8 of 62 (permalink) Old 02-17-2019, 12:04 PM
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You can tell how busy a man has been by the pile of sawdust on the floor. You've been busy.

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post #9 of 62 (permalink) Old 02-17-2019, 12:05 PM
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It wouldn't be symmetrical, if it were cut. You would lose the thickness of the blade. Did you ever do sand casting in school?

Real trucks dont have spark plugs.
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post #10 of 62 (permalink) Old 02-17-2019, 12:15 PM
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If you are asking if I have done Sandcasting in school. If I did, that was a long, long time ago. So I would have likely forgotten by now. Never liked School much anyway,LOL
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