Foundry Sand Casting Ramming Tool

This is sort of part 3 for my two foundry instructables. In this short ible I will show how I made a ramming tool for my sand casting future projects. The idea is very simple and done in a few steps.
Links to my first two ibles on how to make the foundry:
Mini Charcoal Furnace
My Second Aluminium Foundry

Making the Ramming Pattern

The pattern I made was from a wooden stairs banister I had in my shed coverd with dust for a few years. It's a perfect size for a ramming tool and has a decorative feature.
After cutting to a suitable size I beveled one edge so it will fit nicely into the flask corners.
A bit of fine sanding and I got a good wood pattern ready.

The Flask

I made a new wooden flask larger then my old one in order to fit my pattern. The flask is made of 2 parts, top is the Cope and bottom is the Drag. On the side I have wood drilled to keep both parts aligned together. The pattern is placed in the Drag part. The Drag is placed upside down at this stage.

Getting the Mold Ready

First I start placing the Petroband over the pattern ramming it with a block of timber and this is where the future ramming tool will come into use. After the drag was coverd all the way up I turned it back up and notched around the pattern half way down smoothing it with a spoon, nail and my trusty finger.
Then a bit of parting powder on top to prevent the drag petrobond sticking to the cope.

Nerve Wracking Part

This is the nerve wracking part separating the cope from the drag and removing the pattern out of the Petrobond.
I removed very slow and gently both parts and the pattern .....SUCCESS , a beautiful mold was created. I made the pouring hole with a metal pipe, another way to do it is by placing a cone shape piece of timber into the cope while ramming the sand and then remove it. On the pattern end part I made a small vent hole (a bit too small).
Then again very slowly I closed the flask and placed a clamp to hold it tight.

My New Aluminum Ramming Tool

This was the hardest part for me, WAITING. I poured the molten aluminum into the flask and the left overs into the slim ingot tray that I made. I let it cool down and then I opened it all exicited to see a beautiful new tool to add to my collection. My new Aluminum Sand Rammer.
I cut off the extra metal from the pouring spout and from the vent hole. After I gave it a light grinding and cleaning and it is ready for use.