Casting and Installing Anodes & Learning to Weld

Casting and Installing Anodes & Learning to Weld

I’m Doug behind me a saving vessel
seeker she’s a big steel boat so she needs a nose and so in this video we’re
making anodes so what happens when you put two dissimilar pieces of metal like
nickel and iron or aluminum and steel together in you and do some with an
electrolyte like seawater you get a battery and what happens in batteries is
the anode material corrodes it’s the one that has basically more electrons in it
they want to move across to the other metal and they do so they fly across
when they fly out of the metal they tear the metal apart so it’s not a good thing
so up there there’s a pilothouse connected to a steel boat not a good
thing especially when you get seawater between the joints so what we do we put
a gasket between the joint we seal up the outside to keep moisture out and we
keep the two separated electronically so they’re not connected metal to metal
that’s metal to rubber to metal so put in a multimeter across them shouldn’t be
any current up there that’s what we’ll test with when we put it together
finally on the rest of the hole we used a notes this is a cheap version because
this is aluminum anode it’s an aluminum and zinc mix and what happens is the
electricity it wants to flow from one part of the boat to another part of the
boat like from the steel to the actually would be going from the from the bronze
to the stainless and from the stainless to the steel and from the steel even to
the steel because different parts of the bows will have different potential for
pushing electrons out into the water so what happens is you bolt these things
onto the boat and the electricity the electrons the ions flow out of the metal
our steel at a 36 miles steel hull which will be kind of lower on the galvanic
chart into the aluminum which is higher on the galvanic chart and there’s some
zinc in here which is even higher on the galvanic chart and it flows from this
out into the water it will tear the snot out of this over a matter of years you
know we’ll get anywhere from 2 to 6 years out of an anode so we’ve got 30 of
them now they’re $65 a piece if you go to the store and buy them we made ours
out of scrap metal cheap is dirt well check this little guy out it is freezing
out here I mean it’s literally 28 degrees that is amazing I said antifreeze for
blood and what I’m doing is I’m cutting these
Anna’s up so I’m just not sure that they actually have 5 percent zinc him because
the Zeke we are having a problem with it oxidizing in the melt so now I’ve got
some zinc ingots I want to mix in with them all right I got a movie someplace
where you’ll be safe a little warmer now huh gotten up to freezing that now 32
degrees what we’re doing is we’re getting growth out of the bottom of our
tank while we siphon it out just so it gets some new diesel in there and this
is Winston yeah it States Navy and then ship builder at Newport News third year
into a four year apprentice is that a good deal for you oh yeah oh yeah you
like it it yeah man you can’t beat it you need to go to school yeah that’s
right he paying you to go to school for electronics you see work mainly on
weapon systems he said yeah combat system the area Island house
Island House you know that’s the stuff that’s a big thing on the carrier and
whether you call that thing I just thought it calls a big thing on carrier
no good to have you here there lately ya see that one there yeah and
this stuff is done amazingly well it’s like you’re number 9 or 10 and it’s got
you call us here at Terror when you pull on it yeah it lasts a lot longer I
thought it would it’s so weird to walk out here after we
take it down it’s like you know the roof was blown off not gonna look pretty if I
get another year out of this thing hi Jenny value during yeah say that air
here nothing broken that old vinyl is tougher on this stuff
than most anything else we’re redoing our anode we weren’t sure
we had enough zinc in them because of the zinc powder that we used so the
first time we made these so we’ve cut them apart and we’re going to make sure
we get it right this time am I out of gas what are you doing is he it’s kind of
like that a really nice thing gets now melting them down we’re putting in some
sinks if we got from Florida there’s some guy down there that gets him off
old boats melts them down into obviously his wife’s cornbread pan and sold them
on eBay so I got these really cheap the beautiful thing is each one of these if
I had to buy them across $65 so we’re saving up boatload of money here today
is that that bloomin ohm is just scrapped that came off of our tender
bill and pilot house bill – and some other stuff
that I had that we just cut up so instead of just taking it to the
scrapyard we’re making a nose but if you do not have a lot of room
they’d be real careful when I bring the songs up
it’s great for five to be hard we’re using a steel bowl that we made
which is working out real well so it’s a matter of figuring out how much water to
put on it too cold and it locks itself to the little symbols where the bolts
will go in the center too hot and you break it in half when you try and dump
it out yes I broke one this morning but these guys have done wonderful with it
are you laughing you were laughing just then so what we end up with this
probably about eight or nine percent zinc and five to mix I think four
percents all you really need that’s what they sell when they sell yeah luminol
man though it has 5% of zinc in it and those are even cheaper than if you
bought the solid zinc ones it’s really no way of knowing how cold is cold
enough again the problem here once your gloves get
wet that heat comes through really thick broke the bones again you asked yeah
we’re good at doing this we are thinking about welding those in I think that’s
what we’re going to do this time we shared the bowls on when this morning –
and Massey here you can see that notch he cut through there cuz through the
bolted in unscrew the bolt well done all three of us and making it hotter bassy has figured out this okay to turn
when the water looks like it’s pasta water I think that means it’s boiling
and what it means that’s too much bubbling I’ve been thinking that’s how
to cut a hole icing frosting right off there your call bell sound really cool man okay got
another close how you doing yeah it is
stay warm good luck alarm it’s not steaming anymore huh guess what we’re
doing tomorrow oh say all right this last – these guys have
done ten of these today yep it’s not even lunchtime yet wonderful
job I’ve been goofing off giving tours this
is Thanksgiving weekend well Thanksgiving week you got one draw using
the scrap that you do think the digging so yeah shut that down in there see
there melts in and this is Frank Frank Moore from Broken Arrow who is dad right
proud dad a little lock in the frost there keeps
the crucible from falling out and the trick is to get that bolt forward easy
thing to do and this mold has lasted really well we broke all the bolts but
we’ve welded the I guess you call them the center pieces in there that’s where
the bolts will actually hold the ingot not he gets the anode onto the boat okay pour the first one put it back into the
furnace just to keep it molten and then they’ll cool this off knock it out do it
again or you not throw that thing down like an
optometrist there is beautiful oh really well did that one on oh it’s just – what
it’s the same one sorry about that Wow
ant sheared the well okay let’s get the punch to drive that thing out of there
you know a third time for doing surgery on the team I asked one canal smiling face jaison’s
with this this morning good morning good morning
I would they just I discovered I went back and playing hey my tool didn’t have
a blade in the box the blades are sold as accessories now
somebody can explain to me how blade any blade just one blade is an accessory to
the tool that’s like yeah okay we’re gonna show you the car but the wheels
and tires well that’s an accessory so so anyway these things aren’t too cheap
either they’re like five six bucks apiece but you know you told they last
pretty good that little saw blade that’s what I see something that would cut
metal plastic and wood and that’s what I got so two of those and a skinnier one
so well give the thing a try that’s pretty good that’s for getting
underneath weird things and you can have fun with it at night in bed burn yet
dead minute have a good I’m not brave enough for this hi no kidding really Jason here is a
counselor – he can he helps me with all my issues I have double personality my
schizophrenia my narcissism it’s a long list of things he’s very qualified
though it’s the abnormal psychology that may fly in this is that grindy bit
that’s way out of balance but one thing you can do to kind of recover because
these discs are like 20 bucks you know what you do they get unbalanced because
people grind really flat that’s kind of a natural thing people do but if you
grind like this you actually bring the dimension of the disc in more and if you
grind flat you’re slowly learning it away this way and that makes it out of
balance so if you can stand it grind like this for a while you probably can
save the disc and put it back in balance again also check to make sure that it’s
actually not as right and center it up there but I love these things I have a
bunch of Dewalt discs that they gave me I do not recommend you ever buying a B
Walt grinding discs they’re cut off this are fantastic they’re grinding discs I
haven’t had one yet that doesn’t just completely suck cuts great so like the
first 30 seconds and then it just goes to like a smoothing process the 3m qubit
Ron always cutting good focus
someone we decided to do is put some stainless steel plates on our hole where
we’re gonna put our anodes on so it’ll be a bolt coming off of that that way if
we you know later on we got we damaged the bolt we can just cut it away weld it
back on we’re not going to jack up the paint on the boat that’s around it now I
will make the anode stand a little more off the boat but you know we’re not
going to be in the Volvo race okay so a little slower anger kills always a case
little more bucket please do Morgan hook there’s out on the ROV and he’s my my
bucket supplier I just walked up with this you’re out here what the hell
happened there I think that actually burned apart cuz I got brittle this is
just the probably this saw is ancient Harbor Freight warranty I just bought
this last week this when you’re feeling comfortable
with it do you eat it my square totally well that’s why I buy them by the Dozen
when I go to Harbor Freight no big deal like a an inch yeah to tell you that
there’s diesel on the other side of that steel okay we won’t be hit man if it is
happen submit hit about 13 percent you know a ratio of diesel fumes to oxygen
fumes and you do make a spark inside the tank it has enough force to put your
body out in the street but it might make me a youtube sensation oh yeah the overhead well zero our pain and I
have to redo them but the ones sitting up on top look at that gorgeous you’re like what the takács is made yeah
that’s like coming back okay yeah write down this stuff it just flows in
like butter yeah yeah first you’ll need to eat use you’ll need to put a smaller
over here and then a smaller on the other side same way you know like
starting that is iodine that’s no big deal
yeah to keep it from tipping yeah now we ground that one out so it to be done
again but look at this one over here and that beautiful a what how much stainless
steel will make welding have you done first one first one let’s get attack on
then up hit it with a hammer to straighten it out right and I really like the whole laid behind
it yeah instead 11x straight on just poured others every little artifact
on the boat when we first built this boat it was big flat sheets of steel and
we had to lift them up turn them over weld on the other side and so this is
one of the holes that was burning through that original plate of steels
that we could put chain through to lift it it’s being passed from the inside I
just gotta grind this out so we get a good weld on from the outside got a peekaboo we’re going over our saying to feel
wells twice just to make sure tightening them up a little bit so
nobody can steal that’s right everybody Tulsa needs each things like that yeah
yeah card you know I was thinking if somebody starts whining too much about
that the laminar flow is gonna be lost always hey we can making the bacon print
not like I do it I can print 3d shit we can just glue it to the hole right there
right straight out the floor around with say with on the yeah yeah it’s gonna be
so shitty coming through here anyway that up there that’s the proper tourney
is gonna pull most of the water from up let you down in it well in the props
turning we’re sailing it long okay so if your board and you have an ABS 3d
printer give them some fairing cones around here that thing is an inch and a
half and it’s oh it’s about two inches actually is like two and a quarter
inches out maybe even two and a half right here something that the fear the
water around the Anna if you don’t do it then don’t whine about it I don’t really
care I think it’ll work fine you know we have gloves that don’t have
holes in them I know but I like to air my knuckles when I think I’ve got to
nuts and one step three notch and one stop now while we’ve been using a
stainless steel and it takes a co2 gas it’s a nice table wire and I’ll you put
the number on the screen here but I tell you what we have learned that it does
not do overhead well that is hard flat down yeah it runs like water but
overhead yeah it runs like water we’re gonna have Turkey yeah I am never going
to eat again okay yesterday was Thanksgiving and wait
desert twine I know I’m Joyce it was so good no I don’t ever have to eat you
yeah that’s gonna last what 10 minutes Tinka your stuff too aren’t you oh yeah
yeah do much gravy oh god the gravy uh-oh no Alexa why do we build a boat
because it won’t build itself so Basti got to experience the full on american
eating holiday oh yeah how was it good we’re gonna export that around the world
easy that’s no problem no pecan pie and that chocolate fudge
pile yeah that was chocolate turn my wire speed down over there that’s at 315
now put it on 300 yeah so I’m just doing the normal ones yeah I’m gonna let
stacked up that’s it then it’ll be easy let me grind that off we’re not gonna
have any divots okay yeah that’s right yeah see nice runs no drips no errors
and then if you want to you can go across and come back mm-hmm you know so
that’s the kind of thing so if it starts getting too hot you know like it’s gonna
blow through then just stop and let it cool down cool this is what it looks like when it’s
done badly because we put a weld into the bottom but it left a lot of gaps but
on the toe of the world or the bottom of the world didn’t go all the way across
the opening so it leaves these big gaps if you just take it and just put it in
slowly across you grind again nice and flush looks great
this will grind out some more these intakes don’t have to be big small
works fine yeah the toes are the well to weigh out on
the side that’s great yeah I start on top of a well and end on top of well and
then you won’t dig up crater yeah see that looks great nice cover yeah that was just too high I should
have done this before I give it to you this is before we farted with the water
speed just too much and just having tendencies that burn through and this is
after so we got a nice bead up there all right so that’s change your welder if
you’re not doing too well quit quit trying to make it work you know nothing
else change the nozzle and the tip it makes you feel so much better a clean
your hood you’ll feel so much better we say goodbye to basse tomorrow he gets on
an airplane the Colorado and the music at the end of this video is brought to
you by basses friend whose channel is approaching nirvana the song and the aim
of the song is so with the Pirates coal pirates call perfect for us you

100 thoughts on “Casting and Installing Anodes & Learning to Weld

  1. Interesting did not know this was the key factor as to why steel hulls corrode in salt water and that there was a method other than paint/coating to help slow it down. Or of course that this was A/the method used

  2. Just a thought, if an electrical fault happens in some equipment, say in the pilot house and shorts to the frame of the house, assuming the boat hull is the "earth" reference for the generator(s)/ invertors. How is this case handled, as if the pilot house is electrically insulated from the hull its a shock hasard. Not being a safety-nanny, but seems an important thing to cosider. also what if lightning strikes the pilot house? .. I know nothing about boats so forgive if im missing something obvious.

  3. Buy the Rockwell blades for your new multi tool…the cheap ones are f**ked and never push hard…let it cut LIGHTLY or you will burn them out quickly

  4. Long time ago, I was using a similar type disc on a high speed grinder that was also out of balance and vibrated severely. These discs mounted against a thick hard rubber backing plate. Long story short, the disc broke apart causing the rubber backing plate to disenegrate and a large chuck flew off and broke my lowest right rib. Dropped me like a rock.

  5. Great work, those blades for the vibrating saw can be resharpened with a triangle file when they get dull. A tip I got from 'seejanedrill' youtube. She is great at giving new makers tips and how too's in her own comfortable style.

  6. What's the advantage of using the mixture of aluminum and zinc for the anodes? The 8-9% by mass equates to only about 3% by mole, so wouldn't the zinc at the surface would just end up dissolving away and leaving a passivated aluminum surface behind? (Kinda like that Cody'sLab video explaining why you need to inquart gold with extra silver to refine the gold.)

  7. How about casting some teardrop shaped anodes with the same stud spacing.
    They would me more streamline through the water?

  8. One quick comment Doug, electrons flow from anode to cathode. The cathode being the steal hull. That’s why the anodes slowly dissolve over time.

  9. I realize you're probably done casting anodes…but would it be worth trying to make plugs from silca sand (the mix that you used to do the bronze casting molds) make a small metal mold to "cast" the sand plug in…then have a bolt welded in the mold to drop the plug down onto, and then pour… that way when you're cooling it off..the sand will just crumble away……

  10. Once again you have a killer crew to help you… I hope he is addicted to pecan pie and your wife teaches him how it is made.

  11. It's the straight parallel surfaces and sharp corners of those pins/bolts which are holding the casting in the mold. To get the anodes to release from the mold you have to taper the sides of those mold projections. And put fillets in the inside corners, and round over the outside corners of the mold projections. In other words, your mold doesn't have the proper amount of draft on the sides of those pins.

  12. My Dad always told me “If you can step across the gap, you can weld it closed” I have learned I cannot step cross any gap more than a 1/4” because I suck as a welder.

  13. Next time hit the bottom of the mold with a metal hammer and see it that helps. I worked at an aluminum reduction plant and they had a pig casting furnace. The molds would flop over and they fell against a metal fence so there was a shock to the mold. Sometimes the water spray that cooled the molds didn't get set just right and the people on the line would hit the bottom of the mold with a hammer. The resulting shock would help the two separate.

  14. Hey DOUG, I think you should get some urban artists painters to do murals on your boat Ie from Tulsa.. that would be so cool. I think many of them would be right on board with the idea.

  15. hope u had a good thanksgiving another great video all this grinding and melting and welding brings me back to the first videos i watched on Seeker take care all

  16. It was nice getting to meet you at the Good of the Land Fest and watching your demos on casting some of the anodes.

  17. I love my multi-tool! It's not hard to file new teeth in the blades when they get dull. First I grind them flush on a vice and then I use a triangle file to make new teeth. Saves me big $

  18. I've always understood the concept of anodes, but didn't fully understand how they work until your description. Thanks!

  19. You would think over the years that you have been using Harbor Freight Tools that they would actually start sponsoring you for a change and get some free stuff.
    Or better yet be there beta tester for all their tools and get paid for it.

  20. I know, I know you hate it when people say " stick rod welding " But in this case stainless stick would be perfect for overhead, tig even better. Thanks Doug for the video.

  21. Doug, Your a no BS kinda guy. I watch about ten channels regarding sailing, boat building and cruising. I haven't watched every video (yet) but yours are very easy to get! Do you have an expected launch date? BTW, you do nice work.

  22. Might have been more convenient to mill a pattern out of MDF to make sodium-silicate molds for your anodes. Its an extra step but you might make it back in burnt gloves pretty quick 😉

  23. Interesting video. As for Grinding discs going out of balance. Consider putting them into a lathe and facing off the surface mounting the disc (5/8" nut) We order by the case loads and face all brands prior to use. Never a problem during their life. Does not matter how thin they are use down to. Thanks — from a life time grinder.

  24. After watching your aluminum boat sponsons leak, I keep thinking about the amateur welding along the lowest seams. Did you do any testing before everything is buttoned up and hard to get at? If you filled the hull six feet deep and checked for leaks, I missed that video. Not trying to be a dick. I just have seen too many things with boats and planes that can be disastrous.

  25. 309L stick works fine for overhead. I know you like the dual shield, but certain welding processes are better for certain applications. Respect. I've been watching you since before you bought the steel.

  26. I hope they pay you more for the 2 minute long ads than they do for the 30-second ones I don't mind watching them as long as I know you are getting paid for them.

  27. 1) You are a great teacher and inspiration. 2) One of the most interesting videos I have seen. 3) Really like your helper from Newport News Shipbuilding (NNS) Apprentice School. 4) I finished the NNS Apprentice School in 1969 and NNS sent me to engineering school for 4 more years.  Really great Company! 5) Now retired from CVNX Engineering Manager doing consultant technical services for NNS on  CVN 80/81. 6) Your You Tube one of the best I have ever seen.  Can't wait till you are ready to put her in the water.  Outstanding!!!!

  28. When you cast in a steel mold, use an oxy-acetylene torch with the oxygen cut off to deposit a layer of carbon all over everything in the mold that will contact the molten metal. Just wave the smokey acetylene flame all over the interior surfaces until they are uniform black. Your sticking problems will diminish greatly.

  29. LOL! YEARS…maybe…as long as you have solid grounding. My boat mechanic showed me a boat that he had to replace two Bravo 3 out drives on (at $20K+ each) because of a bad ground. ONE WEEK and the out drives were eaten away to nothing. Bad ground at the shore power…He had about 4 or 5 pounds of anodes (for fresh water) and those were completely gone…as well as his out drives. Yes, you SHOULD get quite a bit of time on those anodes, as long as you have no eddy currents due to some lifted grounds…and on a boat like yours I can see it happening mainly because you'll be re-configuring Seeker based on what the mission is. Regular inspection will be needed….

  30. Tip: to weld bolts or studs to any substrate; get a short length (12" approx) of rubber hose that just slips over the bolt/stud, air hose works best for me. Protects threads, hands, and makes it real easy to reach into tight areas. Hose will burn after several bolt/studs so have several hoses to let hot ones cool. enjoy your channel.

  31. My boat has 16 zinks the same size as yours. Aluminum weighs 16 lb. and Zink is 28 lb. I get them for a company called M and M Industries, in Chester, PA. Last time I bought them, the aluminum ones were 25.20 each. the zink was 38.00 each. Both type come with a piece of steel bar stock cast in. The steel bar mounts to the studs on the hull. This way the anode doesn't get loose as the anode degrades. I get about 5 years out of a set of the zink type. I just installed the aluminum type a few week ago, so i don't know how long they will last yet. How this helps.

  32. Would it be worthwhile experimenting with a core sand to create the holes in the anodes? Also, fry pan non-stick spray is really good for stopping weld splatter sticking to anything you're welding. Really good video.

  33. Here's a print file for your wedge I've set the dimensions at 2 x 5.5 x 10 with a 0.2fillet on the top outer edges. If you can give me overall dimensions, I could design a wedge which would surround your anode completely if you like, kind of like a wedged donut.

  34. In the colder weather, have you tried doing some pre-heating of your materials to see if that helps with the welding? Been watching a guy that works in a rather cold shop in the winter, and I noticed that he does that with the heavier materials. I guess the cold metal was pulling the heat away from the weld and making things difficult until it had absorbed enough to keep a proper temperature at the bead…

  35. Worked in the wood floor industry for 10 yrs. We would just make our own blades. The ones they sell dont last long enough to justify the price.

  36. Drill 2 holes in the mould, weld in 2 nuts on the outside and keep bolts in while pouring, after pouring and sink has set. Continue screwing in the bolts to press out casting.

  37. FYI. We , in the uk, built Destroyers in the 70's on the cheap with aluminum superstructure …….. then they sent them to the Falklands where they got hit by French made Exocite cruise missile. Burned up fast killing a lot of good sailors. Hopefully you won't have that problem.
    Real Land rovers had aluminum bodies on steel frames , that's why you don't see many old ones! The corroded away on salty roads.
    Cheers Warren

  38. Doug, Glad to hear you are using Zinc/aluminum anodes. We do work for these guys who make just that sort of alloy. Pure zinc is not as good, but it's hard to convince folks of that.
    Cheers warren

  39. Hi! Last time I was working in a yard replacing anodes the new ones where curved making them more aerodynamic (aqua dynamic?) and thus not needing any additional faring etc. Could you make the mold smoother?

  40. When installing the anodes on my boat I always place some waterproof grease between the anode and the metal surface to make sure the anode doesn’t corrode between boat and and anode. You want very low resistance between the boat and the anode.

  41. Make a bunch of thin steel sleeves for your anode holes. Just get some thin walled tubing and spit them out on the lathe. Then they won't stick to the mold.

  42. watching you taking the crucible out of the foundry reminded me of all the trouble you had casting those porthole covers

  43. I used to work in the aluminium industry. There they used a blue paste they painted the launders and moulds with. I think it was boron chloride? As a high temperature mould release agent.

  44. Hi guys. Do a little homework on this, but : Don't put stainless plates (& bolts) on a mild hull to bolt your anodes on with. Rather beef up the area of the hull with thicker mild plate and use mild bolts. Otherwise, all you are doing is introducing a much more noble element (stainless) into the mix, which will not only speed up your anode burn, but also introduce a real threat to your hull plating if your anodes burn off before you get chance to replace them.

  45. I love how you said "It runs like water" as both the pro and the con of the welder wire, because I say stuff like that where what looks like a good thing from one perspective looks to be a bad thing from another. (~_^)-b

  46. I'm a bit late to this party but a quick thing I have learned on those oscillating tools; keep your pressure to a minimum. They seem to do best when they do the work. I think when you push in they have issues clearing the chip and based on how flimsy the blades are they tend to go off track really fast. I have just learned to spend my effort keeping them on track not pushing them in.

  47. Great video thanks for answering my question about the metal and salt water solution for the boat. 🙂 Hey it might help to weld a rod onto your mold for easier moving and not getting the gloves to hot when knocking the anode out. It may make your work easier if you make more again. Thank you for sharing.

  48. I stoped watching youtube for a while but recently came back, Good to see where everything is at. I can't wait till it is launched will be very cool too see. Hopefully I'll get to come by and help sometime within the next few years now that I'm legally an adult.

  49. great job guys, just a suggestion, why not weld a piece of flat bar in your anoid mold on a 45 accross one end of the mold, so the anoids have a tappered edge to help with water drag, cheers

  50. If your METAL grinding discs stop cutting, start the machine and rub it a few times on a slab of concrete, then try it, YA HOO.

  51. Why not slope the leading edge of the anodes? Do they produce measurable drag being attached, shaped like a brick?

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