Build a foundry and sand-cast aluminum.

Step 13 Operating the furnace.

I had several instructional videos to show you, but my mother managed to unintentionally delete them off of her camera.

The world weeps.

It's O.K. though, operating the furnace is pretty straight-forward.
All you really need to do is

1.Fill the crucible of aluminum scraps
2.Cool the tongs in water
3.Let the aluminum melt
4.Use a metal pole to remove dross (Gross stuff floating at the surface)
5.Cool metal pole in water.
6.And repeat

If you don't have a gas-mask then you need to hold your breath when you feel hot air from the furnace hitting your face

Aluminum scraps should be melted in this order; can tops, can bottoms, and then can sides.
This is in order of metal-to-dross yield.

Dross should be removed quickly after the aluminum melts, or else it will clump together with some of the aluminum and stick to the sides of the can, reducing the amount of pure aluminum you can get per pour. There are some pictures of me removing dross below.

Also you must be careful with hot tools, not only because they can burn you, but because they can burn other things.

For example, If you use hot tongs to try to grab coal out of the coal-bag, the coal could ignite setting the entire bag aflame.

When you notice that the crucible's glow is starting to fade, either add more coal to the fire, or prepare your mold for pouring.

Comments

[thrasher308]

I do not see a full face shield in these photos, I would suggest that one be obtained and worn when close to the furnace, as even a drop of sweat could cause a "Pop" and spray of molten metal. Trust me, you will be thankful you did, at some point, if you do much casting.

[canis]

i'd repeat myself, but thrasher did it for me. face. mask. or no face. you pick.