Melt Aluminum for $3 and some begging!
Step 1: Begging and Buying
The Sauce Can Foundry
This is a really fun project that doesnt take much time at all and once completed enables you to melt metal!
::Warning::This activity does involve fire and very high temperatures, so bring your common sense and competence along. You should engage in metal melting activities fully covered, wear leather boots, jeans, and a long sleeve shirt. Use eye protection and gloves over your hands.
- 2 used Papa Johns sauce cans (just walk in and ask for a couple, early morning or early afternoon is usually when they prep sauce)
- 1 used bean can
- 4 inch diameter x 24 inch length Galvanized Oven Vent
- Blower with a power source
- A few screws or rivets
- Foundry stand (jackstands and a grate in my case)
- Can opener
- Flathead Screwdriver
- Drill with proper bits
- Sheet metal bender (in my version)
- Tin Snips (scissors might get it done too)
- Cans or other forms of aluminum
- Welding Gloves
- Lighter Fluid (optional)
- Tongs or a coat hanger for holding the crucible
- Spoon with extended handle for dross Removal
- Eye Protection
- Somewhere to put the molten metal, I used a muffin tin.
If there's something in this list that you dont have or cant get then try and improvise (except on the safety stuff). The first time I made one of these furnaces the duct was made from left over rain gutters. And the blower came out of a microwave. Just give it a little thought and start building and see what you can come up with.