How to Save Money When Buying decorative aluminum castings

With interesting projects comes the possibility for interesting problems or as a recent Instructables competition puts it, Epic fails.

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Maybe I should be concerned that when I checked the emails this morning and saw the competition for epic fails that I had at least 2 options ;)

I have been melting metal for a few years now, in this instructable I will detail a few of my experiences along the way and a few things that I do not recommend for your own safety.

My first metal melting experience was with a coal fired foundry. It was created with a 20 litre stainless steel bucket on the outside and a 4 litre bucket on the inside, a pipe came through the side of the bucket and was connected to a vacuum cleaner on blow. The space between the 2 buckets was filled with normal concrete and while it did melt metal it also spewed small hot coals once it burnt down a little.

My first crucible was a section of 100mm galvanised pipe with some steel plate welded to the bottom. 5 or 6 years ago when I made this earliest foundry I did not have the skills to make the crucible myself so one of the fitters from work made it for me. While I no longer use I do still have it.

The photo above is pretty much my second foundry. It was LPG fired and was reasonably effective.

Like the first foundry it was made with ordinary concrete and through some miracle it did not explode or spit at me.

In ordinary concrete the cement adsorbs the water in the mix thus at high temperatures it can release the water.

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Water is many times the volume in steam form (1600 x I heard once) and water turning to steam inside a closed volume can result in extremely dangerous steam explosions where concrete can go flying.

In the photos above I am melting brass from old tap ware in a commercial clay graphite crucible bought off Ebay.

In the second photo I have poured the brass into my so called 'metal muffins'.

As you can see here muffin tins make great ingot molds

PONTALBA - H 18" x W 6-3/8" - CAST - ALUM

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Item # AL20.201 H 18" - W 6-3/8" | This classic aluminum casting is durable - perfect for any of your projects. It's easy to install and has a modern design that will work for fences of all shapes and sizes.

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