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Ceedawg, what do you do for a living?Do you have any experience in such matters of a foundry, casting, manufacturering resource material gathering, logistics?

First thing I would cut up a 318 block, reverse engineer the sand molds,
This is the basic no brained to the matter but does have the massive short comings in several different venues. Though I’m sure you have noted such deficiencies already.

I would love to hear about the mold making process myself.
why would you start from scratch?
Who said anybody started from scratch? Though that would be an excellent idea minus the basic perameters of what it is your replacing and for its use.
YES! If it is so simple, why didn’t you name a foundry?
Why not use the ones that's working now for the other guys?
Now there’s a statement on showing the world here at large that you have absolutely no idea on this matter.
Do tell us all why not as well as what are the “Other Guys Using!”
Finding a competent machinist would be the biggy.
That should be the easiest part. Not to dumb down any machinist here but the extent of the machine work needed to finish a blue print on a square block is a basic and simple chore. I have seen what area machinists have to perform for the final exams and regular tests. A good fella down the block had to make a flash light out of a small billet. He was given the billet and the electrical parts to construct the flash light.
Many overthink too much.
I think you under think this.


Bring on the money.[/]
Whoa! Wait a minute here. You said this was an easy thing. You make’em, I’ll buy them.
Get to work, we are all waiting.
Why would you need money up front?


They put a man on the moon with slide rules, some of you guys don't have the guts to try anything that's "too hard" because "someone" told you that.
Right back in your face brother!
Let’s see what you hit. Bust out the work!

Where would we be today if all the thinkers-inventers listened to that way of thinking? "Mommy its to hard" maybe the big thinkers are on the other side.
Truly for what I think would be the issue for most of us here is simply the cash outlay that you don’t seem to have an issue with.
Must be great to have money pouring out there *** like Niagara Falls!

Due keep us informed on your progress.

As to what model block are you starting with to copy? Have you evaluated the percentage of iron to nickel content and where you will resource the metals from? I personally don’t know where the mines are located to look for iron or nickel much less a foundry to mix pour and create ingets for repurposing for casting would be.

However, how much material would you need to purchase and at what rate that it would be a profitable solution regarding the offset of labor to energy costs vs sale rate of rough product at the level sufficient for consumption much less the steeped side of finished units ready to run or for run vs rough and finished. You know the same level that was offered by MP.

Speaking of which, they had many offering of what appeared to be the same thing but not considering the divorced and married internals of the cylinders.

Did you have an idea of the sleeve material and thickness by chance. I figure that would be an upfront issue reguarding immediate sell.