Step 6: Casting
Take that nice gooey thermite that you worked so hard on and carefully slop it into whatever you are using as a mold. This ice cube tray worked very well as I wanted something small and reusable. Since the shape of the ice cube tray is larger at the 'bottom' I didn't have any trouble removing the cubes.
Keep in mind how the thermite will harden inside an object when you are deciding what you want to use as a mold. Something like a bottleneck vase for flowers would never work unless you planned on breaking the vase off of the cast thermite once it had dried.
Once it has solidified, (it should only take about a half hour to 45 minutes to), pour off the water and remove it from the mold. According to the anarchist cookbook, these will have to dry in the sun for a week, more or less depending on the size of the cast. Alternately you can place them in a oven or dehydrator to dry them much faster, probably in a matter of a few hours, which is the method I use.
Whatever you do, dont put them in your microwave. I doubt they would ignite, but as they are basically chunks of metal, I don't think your microwave would appreciate it. Once again, I'm not liable! Be smart!
As for ignition, thermite requires extremely high temperatures. If it was normal powdered thermite that we were talking about a magnesium sparkler would do the trick, but not for cast thermite. This requires something like the heat from a propane torch, (don't try it, you would have to be far too close to ignite it.) I use something called First Fire Mix. Google it or check back in the near future, as my next instructable will be on making a basic igniter for thermite.
That's it, you're done! If you need any help, check back or comment/pm me, I would be more than happy to help. This is my first instructable, so let me know how I did!
*Edit* For those of you who still need help lighting thermite and other difficult to ignite materials, check this out.
Enjoy your new cast thermite!