Ok here is the deal, We need to create off a existing part a run of valve covers and they need to be cast aluminum. Who,what,where,how do we get this done without being raped in tooling? We are a full machine shop but never made a mold for aluminum....any foundry owners or little guys want to take a stab?

If you could send me a few images, Qty, and timelines I certainly would try to give you a price...

Other considerations would be if you have a preference in alloy composition and the degree of finish ie; flashing fettled off or machined & ready to mount...

Any painting or logos to be added (always brand your products...)

I think you'll get a sense of what level my foundry is at via the link below.

Well Frank you ready to cast a full size valve cover?

Like I said, I need more info... Is this for a Turbo Cummins or a Briggs & Stratton... Dimensions, Qty Etc...

they are a fuillsize V8 valve cover 3.375 inches tall ... pm me your contact info

I have an existing part I can send you

If you think that the tool shop is going to "rape" you on tooling, then I welcome you to try to design & build the req. tooling for your project.
Like you said you are a full machine shop, so you should have no problem getting a book on designing/building diecast dies and going for it, good luck.

Thanks for the helpfull post....we will do it ourselves

Have you made your mold yet?
You never said the quantity of parts needed.
Are you going to machine them yourself?
What is your timeline?
I might be interested if there is enough work to make it worthwhile.
I have a few cncs and a small aluminum foundry.