This is sort of part 3 for my two foundry instructables. In this short ible I will show how I made a ramming tool for my sand casting future projects. The idea is very simple and done in a few steps.
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

The pattern I made was from a wooden stairs banister I had in my shed coverd with dust for a few years. It's a perfect size for a ramming tool and has a decorative feature.
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

I made a new wooden flask larger then my old one in order to fit my pattern. The flask is made of 2 parts, top is the Cope and bottom is the Drag. On the side I have wood drilled to keep both parts aligned together. The pattern is placed in the Drag part. The Drag is placed upside down at this stage.

Step 3: Getting the Mold Ready

First I start placing the Petroband over the pattern ramming it with a block of timber and this is where the future ramming tool will come into use. After the drag was coverd all the way up I turned it back up and notched around the pattern half way down smoothing it with a spoon, nail and my trusty finger.
Then a bit of parting powder on top to prevent the drag petrobond sticking to the cope.

Step 4: Nerve Wracking Part

This is the nerve wracking part separating the cope from the drag and removing the pattern out of the Petrobond.
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

This was the hardest part for me, WAITING. I poured the molten aluminum into the flask and the left overs into the slim ingot tray that I made. I let it cool down and then I opened it all exicited to see a beautiful new tool to add to my collection. My new Aluminum Sand Rammer.
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.