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Thread: Modifying the Master Caster for HATCH automation

  1. #1
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    Modifying the Master Caster for HATCH automation

    If I was ordering a Master Caster and planned to automate it, then I would order it this way.
    XXX volt Master Caster, Subtract thermostat, ADD thermocouple.
    here is a thread when I ordered my replacement -> http://castboolits.gunloads.com/show...-Caster-Option


    You need to read over this thread -> http://castboolits.gunloads.com/show...-Master-Caster

    The changes are simple - No spring is needed and the 5 inch movement air cylinder has been changed to double acting.

    Lead pour parts
    1 – 91251A370, 5/16-24 x 3” SHCS, $7.02 (for mounting 1/2” stroke cylinder to lead valve)
    1 – 6498K195, SST air cylinder, 3/4” bore-1/2” stroke, spring return, nose mount, $18.02 (AD-A12005SN $12)
    1 – 6498K42, rod clevis for 3/4" bore, $4.08
    1 – 4501K72, 1/4" SCH40 brass pipe, 12”L, $8.88 (for 1/2” stroke cylinder stand off)
    Movement parts
    1 – 6071K12, forged clevis end, 1/4-28, $4.98
    1 – 8975K483, 6061 aluminum bar, 5/8 x 1-1/4 x 12” long, $9.31 (for nose mount cylinders, stand off and pivot) -not needed if you buy the rear bracket from me
    1 – 6498K637, SST air cylinder, 3/4” bore-5” stroke, double acting, nose mount, $39.50 (AD- A12050DN $22)
    2 – 97345A578, SST 5/16 x 1/2”L shoulder x -20 shoulder screws, $3.54ea (for 5” stroke cylinder) - not needed if you buy the rear bracket from me
    Air parts $120

    2 – 62005K333, flow control valve, 3/8-3/8” tube, $27.70 - goes between movement air valves and air cylinder
    10 – 5112K65, nylon tubing, 3/8” OD, $0.77/ft
    2 – 5779K157, tube swivel, 1/8" MIPS-3/8” tube, $5.10ea - 1 for lead pour, 1 for movement (under pot)
    1- 5779k115, Push-to-Connect Tube Fitting for Air, Straight Adapter, for 3/8" Tube OD x 1/8 NPT Male - for rear movement air cylinder
    2 - 5779K36 , Push-to-Connect Tube Fitting for Air, Tee Connector, for 3/8" Tube OD , $6.60 ea - to feed air valves
    5 - 5779k116, Push-to-Connect Tube Fitting for Air, Straight Adapter, for 3/8" Tube OD x 1/4 NPT Male
    1 - 5779K158, Push-to-Connect Tube Fitting for Air, 90 Degree Swivel Elbow, for 3/8" Tube OD x 1/4 NPT Male
    The above Air parts list is a SUGGESTED list. I removed the Air regulator because it was discontinued.
    I will post a picture of the layout in a week and update this post
    LOOK BELOW FOR ALTERNATE CHEAPER SOURCE

    Now modifications to the MC
    Rear bracket
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    You need to verify measurements because each machine is different.
    The above pictures have brackets that were made specifically for a particular machine as there is no washers between frame and bracket.

    The opening between the frame should be around 5 inches. I say "should be" because these frames are all castings and there is some differences.
    I would make the bracket 4.5 inches wide. This allows adjustment via washers to move it side to side. You can make it exact provided you make exact measurements.
    The based on a 4.5 width bracket, the bracket is drilled 2.5 inches from one side and tapped 5/8-18 NF. This is for the movement air cylinder. This hole is off-centered because again each machine is different and it allows for adjustment. You can take measurements on your machine and get it exact.
    The ends of the bracket are drilled and tapped 5/16 standard. I would do this 1/2 inch from the top of the bracket. Make the depth 1 inch and thread it as far as the tap allows.

    2 x 5/16 holes on either side of the frame for the rear bracket
    The 5/16 drilled pivot is 2.075" from the absolute back of the MC and 2.900" down from the machined top of the aluminum where the pot sits...both sides...confirm this...this places the 5" stroke cylinder with about 1/4" of extension and contraction remaining in the stroke...important...

    Lead pour bracket

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    I personally use a piece of flat bar alum that is 1/8 thick
    You drill and tap 2 holes that are EXISTING in the lead pour bracket. These are the 2 holes that aren't being used.
    You tap them 5/16 x 24 (FINE THREAD) because there isn't a lot of theading area and you want to get a good mechanical bound.
    Buy the drill bit and tap from here -> https://www.amazon.com/DRILL-BIT-SET.../dp/B01LZZ7OX1
    This plate has 3 drilled holes. Two are for the mounting bolts and one is for the lead pour air cylinder.
    The easiest way to mark the plate is to lay the factory lead pour bracket down on top of it.
    You mark the 2 holes that your drilled and tapped earlier and then you have a hole under the spring that you mark.
    The hole for the air cylinder is a 1/2 inch

    You will need to also drill a hole in the lead pour lever. I do this after I have mounted all the lead pour stuff so I get it in the correct spot.

    Limit switch mounting
    Picture of switch provided
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    I am working on providing a mount for it but here are some pictures of others mounting
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    What I would do is like the 2nd picture.
    Put a piece of metal on the arm stop.
    Then mount the limit switch on a L bracket
    The arm from the limit switch can be bent to make adjustments
    Last edited by HATCH; 01-06-2018 at 02:58 PM.

  2. #2
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    The bracket I sell
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    My setup for lead pour
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    Last edited by HATCH; 11-23-2017 at 08:49 PM.

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    Click image for larger version. 

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    This is my setup.

    The regulator/water sep/oiler came from Amazon for $20

    The middle valve is the modified one. It is the UP
    The top and bottom are the same. They can be either lead pour or down. Doesn't matter as its how I wire it.
    I plan to do the following

    Down
    UP
    Lead

    You put the flow regulator between the valve and the air cylinder.
    You need one on the UP and on the Down

    Fittings used

    2 branch Ts 3/8 tube - 1/4 npt
    2 90 3/8 tube - 1/4npt
    3 straight 3/8 tube - 1/4npt

    I did use a additional straight on the incoming air for the regulator and will use another one on my supply air line

    Here is a picture of it wired up.
    Notice the placement of the flow regulators
    Click image for larger version. 

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    Last edited by HATCH; 12-30-2017 at 10:00 PM.

  4. #4
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    Alternate source for material

    www.automationdirect.com

    FVU38 - pneumatic push-to-connect fitting, inline flow control valve, thermoplastic (PBT) body, (2) 3/8in tube connection(s). Package of 2.
    MS38-18N - pneumatic push-to-connect fitting, male, straight, nickel-plated brass body, nickel-plated brass threads, 3/8in tube to 1/8in NPT connection(s). Package of 5 - $6.50
    ME38-18N - pneumatic push-to-connect fitting, male, elbow, rotating, thermoplastic (PBT) body, nickel-plated brass threads, 3/8in tube to 1/8in NPT connection(s). Package of 5. $11.00
    MS38-14N - pneumatic push-to-connect fitting, male, straight, nickel-plated brass body, nickel-plated brass threads, 3/8in tube to 1/4in NPT connection(s). Package of 5 - $6.75
    ME38-14N - pneumatic push-to-connect fitting, male, elbow, rotating, thermoplastic (PBT) body, nickel-plated brass threads, 3/8in tube to 1/4in NPT connection(s). Package of 5. $11.00
    MBT38-14N - pneumatic push-to-connect fitting, male, branch tee, rotating, thermoplastic (PBT) body, nickel-plated brass threads, (2) 3/8in tube to 1/4in NPT connection(s). Package of 5 $13.00

    A12005SN - pneumatic air cylinder, non-repairable, 3/4in bore, 1/2in stroke, single acting, front nose mount. $12.00
    A12050DN - pneumatic air cylinder, non-repairable, 3/4in bore, 5in stroke, double acting, front nose mount. $22.00
    ARC-14-28 - NITRA rod clevis and hex nut, 1/4-28 UNF thread, zinc plated steel. For use with A-series cylinders. $3.25


    I am going to start offering a kit that contains all the pneumatic fittings you need.
    Basically its gonna be cost plus 10% but as you can see by the above pricing that is a huge savings.
    You still need to buy the forged movement clevis from the other place because it isn't offered at AD
    Last edited by HATCH; 01-01-2018 at 12:45 PM.

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    Click image for larger version. 

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    Don't like being hammered by the Cast Boolits Staff, then don't be a nail.
    The rules are simple to follow.

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  7. #7
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    Can you post instructions on electrical connections to switch and solenoids for those of us who have never connected to a solenoid?

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Abbreviations used in Reloading

BP Bronze Point IMR Improved Military Rifle PTD Pointed
BR Bench Rest M Magnum RN Round Nose
BT Boat Tail PL Power-Lokt SP Soft Point
C Compressed Charge PR Primer SPCL Soft Point "Core-Lokt"
HP Hollow Point PSPCL Pointed Soft Point "Core Lokt" C.O.L. Cartridge Overall Length
PSP Pointed Soft Point Spz Spitzer Point SBT Spitzer Boat Tail
LRN Lead Round Nose LWC Lead Wad Cutter LSWC Lead Semi Wad Cutter
GC Gas Check