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How to make a simple backyard foundry for less than $20, for
melting pop cans,and casting aluminum.
Step 1: Watch the Video
(http://cdn.instructables.com/FYT/LW85/I4UNMTA5/FYTLW85I4UNMTA5.LARGE.jpg)
About This Instructable
Posted:Jan 15, 2015
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How To Make The Mini Metal Foundry
http://www.instructables.com/id/How-To-Make-The-Mini-Metal-Foundry/?ALLSTEPS
1 de 15 26/01/2015 02:46 p.m.
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WARNING: Charcoal foundries can reach temperatures in excess of
1,000C,which is well above the melting point of hobbyists. This
project should only beattempted with adequate knowledge and
training, proper protective safety gear,and in a fire resistant
area with adequate ventilation. The sparks flying from thefoundry
can ignite fires, and the fumes from burning dross can be toxic.
Usecaution and common sense. Use of this video content is at your
own risk.
Step 2: The Mini Metal Foundry
In this project youll see how to use equal parts of sand and
plaster, to make asimple backyard foundry, thats powerful enough to
melt scrap metal in seconds,but still pleasant enough keep around
for decoration.
Step 3: Things You'll Need
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How To Make The Mini Metal Foundry
http://www.instructables.com/id/How-To-Make-The-Mini-Metal-Foundry/?ALLSTEPS
2 de 15 26/01/2015 02:46 p.m.
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Start this project with a big bag of play sand, and some plaster
of paris. Both ofwhich you can find at your local hardware store,
for under $20.Youll also need a 10 quart steel bucket, and a
tablecloth to cover anythingimportant, because chances are this is
going to get a bit messy.A 2.5 quart bucket can be used for
measuring the ingredients, but it also servesa more important
purpose that youll see in just a second.The recipe for this
makeshift refractory lining, is 1-3/4 buckets full (21 cups)
ofplaster of paris, 1-3/4 buckets full (21 cups) of sand. And 1-1/4
buckets, filled (15cups) with water.
Step 4: Refractory Mix
(http://cdn.instructables.com/FG8/3TID/I4UNMTGB/FG83TIDI4UNMTGB.LARGE.jpg)
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How To Make The Mini Metal Foundry
http://www.instructables.com/id/How-To-Make-The-Mini-Metal-Foundry/?ALLSTEPS
3 de 15 26/01/2015 02:46 p.m.
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The moment the water touches the dry mix, the clock starts
ticking. Youve onlygot about 15 minutes before it all hardens up.
So get busy mixing everythingtogether.Its really important to get
all the dry powder wet, and work out any lumps asquickly as
possible.
After mixing for a couple of minutes, it should be fairly runny,
and roughly all thesame color. When youre convinced there arent any
clumps of powder left in thebucket, the refractory mix is ready for
pouring.Carefully transfer it to the steel bucket as slowly as
practical, to minimize thesplattering. There should be just enough
fluid to fill the bucket about 3 from thetop. Now bring back the
plastic measuring bucket, and use it to form the centerof the
foundry.
Fill the bucket with water, to give it a bit of weight, but
anything like sand orrocks will work as well. As you push the
bucket into the center, the mixture risesupward, but it wont spill
out.
Before the mix is starts to firm up, try working the bucket up
and down a fewtimes, to help level it before it sets. Now hold
still for 2 to 3 minutes. This willgive the plaster just enough
time to harden, so the bucket stays in place, evenwhen you let
go.Time for a little cleanup.
Step 5: Clean Up
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How To Make The Mini Metal Foundry
http://www.instructables.com/id/How-To-Make-The-Mini-Metal-Foundry/?ALLSTEPS
4 de 15 26/01/2015 02:46 p.m.
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Everything will still need about an hour to really harden up,
but the plasters stillsoft enough that you can clean and shape it
to look really good. And while yourehere we may as well wipe the
bucket down as well.
Dampen a rag and gently drag it around the top, the surface
cleans up prettynicely, and gets a cool texture in the process.
When it looks the way you want ittoo, simply leave it for about an
hour.
While youre waiting, turn an old steel fire extinguisher, into a
custom crucible.
Step 6: Making the Crucible
You can tell its made from steel because a magnet sticks to it.
And magnetswont do that to aluminum.
Depressurize the tank and unscrew the valve from the top, to
make it safe andeasy to cut in half with a hacksaw. Which should
happen in less than a minute.
The bottom part of the extinguisher is what you want for the
crucible, becauseits basically a steel cup 3 in diameter, and 5
tall. Thats going to be perfect foryour custom backyard
foundry.
(http://cdn.instructables.com/F7Y/A54C/I4UNMTR5/F7YA54CI4UNMTR5.LARGE.jpg)
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How To Make The Mini Metal Foundry
http://www.instructables.com/id/How-To-Make-The-Mini-Metal-Foundry/?ALLSTEPS
5 de 15 26/01/2015 02:46 p.m.
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Step 7: Making It Professional
At this point, the plaster should be pretty well set, so dump
the water from thebucket, then use something like a pair of channel
locks, to grip one edge of thepail, and pull gently toward the
center.Grip it with both hands and give it a bit of a twist, you
can see the whole bucketpops loose, and pulls right out. This just
created an amazingly smooth surface,which gives this makeshift
foundry, a surprisingly professional look.The only features you are
missing now, are an air supply port, and a lid, somake those
next.
Step 8: Lid & Supply Port
(http://cdn.instructables.com/F5C/0J4K/I4UNMTRM/F5C0J4KI4UNMTRM.LARGE.jpg)
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How To Make The Mini Metal Foundry
http://www.instructables.com/id/How-To-Make-The-Mini-Metal-Foundry/?ALLSTEPS
6 de 15 26/01/2015 02:46 p.m.
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A 1-3/8 (35mm) hole saw is the perfect size for accommodating
this 1 steeltubing, and if you center the metal cutting blade with
the top line on the bucket,you can carefully begin cutting through
the metal wall.Once through the metal, its easy to burrow down at
about a 30 angle becausethe plaster hasnt fully cured, and cuts
away like butter.
Now you have a tight, downward sloping hole, that the blower
tube fits perfectlyinto, and its strategically placed, a few inches
up from the bottom. This way, if acrucible fails, and dumps molten
metal into the foundry, it will stay in the foundry,instead of
dangerously flowing out of the pipe.The blower tube is really easy
to make. Start with a 1 steel pipe. This is thebusiness end that
will sit next to the hot coals in the foundry. Youre also goingto
need a 1" PVC coupling (Slip x FIPT), as well as some 1 PVC
pipe.You can see the threads on one half the coupling screw onto
the steel pipe, andthe slip adaptor on the other end, simply pushes
onto the PVC tube. Its thateasy.
Now go one step further and make a lid to help retain the
heat.Get a couple of 4 U-bolts from the hardware store and stand
them upright in a 5quart, bigmouth bucket, filled with a
half-measure of our insulating mix. (10 cupsplaster, 10 cups sand
,7 cups water).After an hour, the plaster should have set, and the
whole thing pops free fromthe bucket, giving you a nice little
custom lid for the foundry.It still needs a vent hole for relieving
pressure buildup, and you could just formone when youre casting it,
or you could try drilling one with a 3 hole cutting sawlike
this.
With the hole in the center, you can see you end up with a nice
thick lid, thatkind of looks like a giant white donut. This design
works great for ventingpressure, and gives you the option to melt
metal as well, without even having totake the lid off the
furnace.
Step 9: Finishing Touches and First Firing
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How To Make The Mini Metal Foundry
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7 de 15 26/01/2015 02:46 p.m.
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Pick up a can of Burnished Amber spray paint, and give the
foundry a coupleof coatings to make it look a little more
attractive.When you get it fired up, the mini foundry gets so hot
on the inside, that it willmelt soda cans within seconds and fill a
crucible with liquid aluminum. Look forhow to do that, in another
project video.With this homemade furnace, you have the power to
liquify aluminum in thebackyard, and cast just about any object you
can think of.The best part is, when youre not melting scrap metals,
rather than taking upspace and looking terrible, you can drop in a
plant, and instantly transform it,into fashionable home decor.
Step 10: How To Melt Soda Cans
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How To Make The Mini Metal Foundry
http://www.instructables.com/id/How-To-Make-The-Mini-Metal-Foundry/?ALLSTEPS
8 de 15 26/01/2015 02:46 p.m.
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We have a be nice comment policy.Please be positive and
constructive. I Made it! Add Images Make Comment
(/member/TDWay/)
5 days ago Reply
With this transforming Flowerpot Foundry, theres certainly more
than meetsthe eye. And by the way, if you run out of soda cans to
melt, you could try usingit as a blacksmithing forge, or even a
bbq, for summertime grilling. After all, it isfueled by charcoal
briquettes.
Well now you know, how to use commonly available materials, to
build the minimetal foundry. Powerful enough to melt metal in
seconds, but still pleasantenough keep around for decoration.Well
thats it for now. If you liked this project, perhaps youll like
some of myothers. Check them out at www.thekingofrandom.com
(http://htpp://www.thekingofrandom.com).
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TDWay (/member/TDWay/)this mis is one option however this mix is
condussive to transferring thru thematerial and will make your
jroje t quite heavy. Have you tried mixing equalparts of slow
setting Plaster of Paris, Vermiculite, and perlite with water till
youget a stiff mortar like consistency? This would decrees the
waight by almost50% and decrees the radiation of heat from the
outside of the vessel
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9 de 15 26/01/2015 02:46 p.m.
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tremendously.
Remove the interior form once it firms to the point it's able to
hold is shape andapply a generous coat of vermiculite to the
interior while is is still moist. Otheroptions to finishing the
interior would be iron oxide , aluminum oxid or TitaniunOxide,
making the interior more resistant to abrasion and reflect heat
back into thechamber.
tytower (/member/tytower/) TDWayIs that dry vermiculite or mixed
with plaster? I have made one withvermiculite and perlite both
mixed in to the plaster sand mix as anaggregate . I'm not at the
fire up stage yet but will post back if it fallsapart anytime
soon.
TDWay (/member/TDWay/) tytowerOnce you remove the inner for
while the plaster is still tacky, you willwant to apply dry
vermiculite and press it in to the plaster, being carefulnot to
deform the interior.
me and some friends made this... thanks for the
instructable!
(/files/deriv/F72/O0VV/I5BRY41H/F72O0VVI5BRY41H.LARGE.jpg)
tytower (/member/tytower/)Well I spent $30 on a steel bucket and
plaster plus I bought a small bag ofvermiculite and a bag of
perlite at $9 each. $50 so far plus handles - mine willbe bits of
bent steel rod with springs around handle part .Only used a
quarterof each of the perlite and vermiculite so far. I thought
that I would try an equalsand plaster mix then add in some perlite
and vermiculite . Its setting now andseems to have gone off hard .
Just looking around now for the pipe and holecutter. I figure if I
don't like this method then I can bore a hole directlyunderneath
and put an oil or gas burner in there or even still feed the burner
inwhere the steel pipe is.
Thanks to the OP as I think this is the best one I have found so
far .I built theone with a 44 Gallon drum and burning wood but it
barely got hot enough forlead and burnt a massive amount of timber
scrap to do it . Has a hinged doorto feed wood in - useless . Trash
burning only
Quaamik (/member/Quaamik/)Nice!
One thing, you don't want to use it for grilling (food) after
you have used it tomelt metal. Far too much chance of
contamination.
HughM (/member/HughM/) QuaamikAs long as you take the crucible
out before your put food over it you'llbe just fine.
Quaamik (/member/Quaamik/) HughM
xinman (/member/xinman/) made it!
How To Make The Mini Metal Foundry
http://www.instructables.com/id/How-To-Make-The-Mini-Metal-Foundry/?ALLSTEPS
10 de 15 26/01/2015 02:46 p.m.
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Contamination from metals is notsomething to play with. Splatter
fromthe crucible, drops or slag that gotinto the coals or around
the top - alloutgass.
Its far safer to use seperate,dedicated equipment for
cooking.
tytower (/member/tytower/) QuaamikConsider yourself a Wowser
void_main (/member/void_main/)Really nice.
In regards to safety, before trying this at home, please search
for "How NOT toPour Aluminum Metal" on YouTube. Very sobbering.
WVvan (/member/WVvan/) void_main
"How NOT to Pour Aluminum Metal"
https://www.youtube.com/watch?v=A796N_YZTm8
void_main (/member/void_main/)I hate to ruin everyone's
enjoyment (by the way love the instructable) butbefore trying check
this out:
https://www.youtube.com/watch?v=A796N_YZTm8
PowellMade (/member/PowellMade/) void_mainTo avoid this are you
to heat the mould?
factoryrec (/member/factoryrec/) void_mainwhen you melt dirty
aluminum it's forming hydrogen, a degassing tabletdisperses the
hydrogen and everything will go fine
TravisB5 (/member/TravisB5/) void_mainDef not a fun ruiner. I
needed to see that to remind me of whathappens when mixing hot and
cold.
deadsy (/member/deadsy/) void_mainCommentary-
1) Use tongs that are long enough to get your hands away from
theheat. Gloves aren't enough. Heat will penetrate thick welding
gloves intime.
2) Don't pour over a flammable or wet surface. When the Al
spills (andit will spill) it will set on fire whatever it
touches.3) Make sure your molds are completely dry before you pour
into them.The pop was probably caused by a little steam explosion.
This sendsmolten metal flying around and that is very
disconcerting.
4) Wear gloves, long pants, boots, a face shield, etc. Cover
your body
How To Make The Mini Metal Foundry
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11 de 15 26/01/2015 02:46 p.m.
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so that you won't get molten metal on your skin or in your
eyes.
And also:
5) Don't pour over concrete or brick. Even concrete that is
apparently dryhas moisture in it. When the metal spills on it
little flakes can explode offleading to the molten metal flying
around problem.
keithmund (/member/keithmund/) deadsyExtremely good advice
here.
WJR339007 (/member/WJR339007/) void_mainRead the video
description, "A little mishap while pouring aluminummetal into a
cold ingot. So this had happened, which rarely does,maybe 1/1000
times at lab.
"
pdu toit1 (/member/pdu+toit1/)i run a brozne foundry i think
this grate little furnes but not very good foranything other than
al
ironsmiter (/member/ironsmiter/) pdu toit1This great little
furnace works PERFECTLY for aluminium, but that isnot it's limit!
Any of the lower melting temperature metals would feelright at home
in here. Tin, Lead, Zinc, etc. Should even work just finefor most
bronze, if you use a proper crucible and hardwood charcoal orreal
coal. Brass, steel, and most of the precious metals are
probablybeyond it's ability, if used as-is.
pdu toit1 (/member/pdu+toit1/) ironsmiteryour right but most
people dont us a proper crucible sadly...stainlees steel is the
connom substitue.... but as long as you play safeand dont be like
me
(http://cdn.instructables.com/FZ2/71GQ/I5A7XR5J/FZ271GQI5A7XR5J.LARGE.jpg)
bradleynelson102 (/member/bradleynelson102/)The link to your
wedsite is broken
loving this time to collect some cans
BAMBAM2148 (/member/BAMBAM2148/) made it!
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12 de 15 26/01/2015 02:46 p.m.
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(http://cdn.instructables.com/F81/XSFA/I5A1UNKQ
/F81XSFAI5A1UNKQ.LARGE.jpg)
(http://cdn.instructables.com/FT6/ZBN7
/I5A1UNL7/FT6ZBN7I5A1UNL7.LARGE.jpg)
(http://cdn.instructables.com
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building mine today. im using a old propane tank for my bucket
total cost athome depot was $46 but i bought double just incase
(http://cdn.instructables.com/F2L/JN9O/I59VX1JY/F2LJN9OI59VX1JY.LARGE.jpg)
zstarkovich (/member/zstarkovich/)Where did you get an empty
fire extinguisher
meeeeep (/member/meeeeep/)Nice! Unfortunately, now I feel kinda
bad trying to compete with this kinda thingduring the Burn It
contest.
Squarcio (/member/Squarcio/)What about the mold? how do i make
my personal? (You're the best anyway!)
mysterygirl995 (/member/mysterygirl995/)Totally going to have to
make this!!!!!!
BAMBAM2148 (/member/BAMBAM2148/) made it!
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spatuladle (/member/spatuladle/)What kind of saftey equitment/
precautions do you need to do thissaftely?
BigW2802 (/member/BigW2802/)and what else would work as a
crucible
BigW2802 (/member/BigW2802/)where do you get 12" of steel pipe
from
wyldaxe
(/member/wyldaxe/)http://rcm-na.amazon-adsystem.com/e/cm?t=tabbooingcom-20&o=1&p=12&l=ur1&category=dominoprojectbooks&f=ifr&linkID=3R56HKFOICXT66EN
Edgar (/member/Edgar/)I always said you could make neat
Instructables, and here's the Proof! :D
Went to my Blog.
http://faz-voce-mesmo.blogspot.pt/2015/01/uma-impressora-3d-super-barata-mais.html
ncdodave (/member/ncdodave/)can I also melt down lead for
fishing weights, using the steel extinguisher?would be more
efficient than using a torch.
Quaamik (/member/Quaamik/) ncdodaveFor melting lead there are
plenty of commercial electric pots availableto the hobbiest. Lee
makes some very good inexpensive ones.
dregalia (/member/dregalia/) ncdodaveThe melting point of lead
is 327(f) 163(c) This is good for up to 1200(f)660(c) atleast to do
aluminum. As long as you don't cross 2500/1370,you should be
alright. I think this would be way better than using atorch, but in
all honesty, you're better off using an electric heater,
orsomething like that for such a low temperature. Look at the
heatingelements you use for 3d printers. a few of those may do the
trick at it'shighest setting. Here are some melting points of
metals
http://www.onlinemetals.com/meltpt.cfm
(http://www.onlinemetals.com/meltpt.cfm)
Ralphxyz (/member/Ralphxyz/)"Just a hair dryer" for air source,
ah thank you I was picturing a bellows.
Thanks for the Instructable, I've just gotta try this just to
make AL ingots fromold screen doors.
Bowtie41 (/member/Bowtie41/)
How To Make The Mini Metal Foundry
http://www.instructables.com/id/How-To-Make-The-Mini-Metal-Foundry/?ALLSTEPS
14 de 15 26/01/2015 02:46 p.m.
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We have a be nice comment policy.Please be positive and
constructive. I Made it! Add Images Make Comment
Do you want the blower hole to be in thecenter of the circle,or
off to the side radiallyto create a swirling effect,or does it
evenmatter?I'm just about ready to start buildingmine,and want it
to be as efficient aspossible,as I'd like to try brass
too.Thanks!
KenC4 (/member/KenC4/)The girl is hot, So is the instructable
thx
starforest (/member/starforest/)This is a great idea! But what
in the world to do with melted aluminum?
Also wouldn't concert or clay be better and more stable the
plaster?
1-40 of97
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English
How To Make The Mini Metal Foundry
http://www.instructables.com/id/How-To-Make-The-Mini-Metal-Foundry/?ALLSTEPS
15 de 15 26/01/2015 02:46 p.m.