Links to my first two ibles on how to make the foundry:
Mini Charcoal Furnace
My Second Aluminium Foundry
Step 1: Making the Ramming Pattern
After cutting to a suitable size I beveled one edge so it will fit nicely into the flask corners.
A bit of fine sanding and I got a good wood pattern ready.
Step 2: The Flask
Step 3: Getting the mold ready
Then a bit of parting powder on top to prevent the drag petrobond sticking to the cope.
Step 4: Nerve wracking part
I removed very slow and gently both parts and the pattern .....SUCCESS , a beautiful mold was created. I made the pouring hole with a metal pipe, another way to do it is by placing a cone shape piece of timber into the cope while ramming the sand and then remove it. On the pattern end part I made a small vent hole (a bit too small).
Then again very slowly I closed the flask and placed a clamp to hold it tight.
Step 5: My new Aluminum Ramming Tool
I cut off the extra metal from the pouring spout and from the vent hole. After I gave it a light grinding and cleaning and it is ready for use.