Finishing Castings

My son is refurbishing a rowing shell trailer for a team he used to row with.
When loaded the shells rest on 2” square steel tube. It is amazing how
many critters use those tubes to build nests. Plastic tube plugs slow them
down, but the critters easily chew through them. Sun degrades them leaving
the tube open for rodents to inhabit.

Friends helped me up with 3D printed patterns for making some cast aluminum plugs
(Thanks to Carl and Steve)
Attachment 49942

Another thread described how these patterns were used to make aluminum castings
Link https://www.homemadetools.net/forum/...m-parts-109156
Attachment 49943

After casting, the parts were separated from the sprue.
Parting line defects were removed with a belt sander
Link https://www.homemadetools.net/forum/...achment-109146
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The parts then required some milling to remove the runner
remnant and some of the casting draft angle.
This was done using a lathe milling adapter.
Link https://www.homemadetools.net/forum/...adapter-101754

Attachment 49946

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All 4 sides are milled for good fit in the tubes
Attachment 49949

Test fit
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Six of the plugs are drilled to for clearance lights.
This operation required soft jaws for my chuck.
LINK https://www.homemadetools.net/forum/...219#post256690
Attachment 49951

The backs bored to reduce thickness for the light grommet.
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The plugs were sprayed with etching printer and painted
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LED clearance lights press into a rubber grommet
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