This instructable will take you step by step how to make a home foundry so you can make quick and efficient aluminum melts for casting. Its propane fueled so its easy to set up and easy clean. I hope it's informative and allows you to make castings of your own. This instructable is a result of my own research and trials I hope it benefits all those who wish to follow into the world of the home foundry.
This not the cheapest furnace but i had to buy a lot of my supplies. If you are a good scavenger/bargain hunter then your total price will be less than mine. Also propane compared to other fuels isn't the cheapest either, but it is clean and efficient.
Warning/Disclaimer: Working with molten metal is extremely dangerous. I do not claim any responsibly for any injuries or accidents that may occur during replication of this instructable. Always be safe when working with high temperatures and molten metal (don't do anything stupid and always wear safety equipment).
Do plenty of research and know what your getting yourself into.
http://www.youtube.com/watch?v=lX6yFQNnk-A (this a charcoal foundry but there is still much to learn from it)
Step 1: Materials
-1/8" hex cap
-1/8" pipe (i used brass but steel would be better)
-1/8" to 3/8" brass fitting
-3/8" to 1/2" steel fitting
-1/2" steel pipe x3
-1/2" T pipe
-1/2" npt to 3/8" nptf fitting
- 1/2" to 1/4" reducer fitting
-1/4" x 2" pipe
-1/4" ball valve
-1/4" male quick disconnet
-3/4" steel pipe about 7" long
-High pressure valve
-Portland Cement (crucial that its portland not masonry)
-Perlite (used in planting it is an aerated volcanic rock that doesn't absorb heat readily)
-Fireclay (i had no supplier of this but i used rutland refractory cement instead)
Furnace in general:
-Steel pots or pails (avoid galvanized apparently if they get to hot the zinc on them will release toxic fumes)
-1" id Steel pipe for burner inlet
-Drainage pipe about 2" long (leftover from making the burner inlet)
-Scrap sheet metal
-Scrap rod of various sizes (i used 1/4 and 1/8)
-Gaffers or duct tape
-flame retardant shirt or jacket
And of course lots of scrap aluminum to melt