Picture of Pizza Sauce Can Furnace
Melt Aluminum for $3 and some begging!

Step 1: Begging and Buying

Picture of 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)
- Hammer
- Sharpie
- Clamps
- Pliers

- Charcoal
- 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.
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Kaiven3 years ago
How do you get the ingots out of the tin? I have six that seem rather stuck.
TALLJ295 years ago
awesome man, i want to build one now
Awesome idea, what other types of metal can you melt?
with that type of furnace, you can melt any metal that melts under 700°C but it's better for a beginner to stay with aluminum because some metals, like zinc and magnesium, can be very dangerous to melt(zinc fumes disease, magnesium fire at over 3000°C).
Cheeseduck6 years ago
I built forge after seeing this instructable, but instead of the pizza can I used bricks, and instead of the bean can I used a crucible from http://budgetcastingsupply.com/. I also used a shop vac as some comments have suggested. I liked the construction of the duct here, and used it as a starting point for mine.

Overall, I think this instructable is a great introduction to 'forgery'
iknowad6 years ago
What can you use melted aluminum for?
callmeshane7 years ago
Do the alumium cakes make your fillings hurt like foil does, or do you just eat them anyway?
I'm sorry... what? i just don't quite understand your question. you dont eat metal. it poisons you (heavy metal poisoning). and what aluminum cakes are you referring to?
sharlston me8356 years ago
hes joking
could you use a 12 volt plastic computer fan for the blower?
fjr122 (author)  MadBricoleur6 years ago
I dont think it would have enough flow. But I dont know how much this A/C fan has. Give it a try and tell us if it melted the metal.
Alright, I'll try when I have time. :D
Shagglepuff6 years ago
Cool! Is it possible you could make a lantern-battery-powered carbon arc furnace?
this is similar to one i made out of a piant can and a shop vac that i reversed =]melts good
thats awesome :-) but, how is the can not melting, but yet the inner metal is ? even if its the same metals ( aluminum can, w aluminum can shards for melting?)
fjr122 (author)  !Andrew_Modder!7 years ago
The Crucible can is made of Tin (or should I say steel), and it has a hotter melting point, but it did get hot enough to glow red. The Crucible can is certainly the weak point in this setup. I'm sure the can's inner coatings contaminated the aluminum. For actually casting things (which I will get around to one day), you would need a better crucible before you needed to improve anything else.
hmm. ok, well i want to build this to melt metal, and i would be using a can probably a small coffee can or a x-large bean can, and i would be wanting to melt steel, aluminum, or mixes in the can would that work? :-\. i really dont know how to explain what im trying to say, like if you had an aluminum can you could only melt aluminum, and if you had a steel can you could melt anything up to steel (melting point) and if you had a steel can with melting steel it wouldnt melt through? Sry for all these questions, but hey if you melt metal you want to make sure it does not go through and cause a river of molten metal to spew all over your stuff :-X!
fjr122 (author)  !Andrew_Modder!7 years ago
Ok, here's a little chart of melting points from lowest to highest
Metal Name Melting Temperature F°
Tin 450
Lead 621
Aluminum 1218
Magnesium 1240
Bronze Cu+Sn 1562
Brass Cu+Zn 1652
Silver 1762
Gold 1946
Copper 1981
Cast Iron 2300
Steel-High Carbon 2500
Stainless Steel 2550
Medium Carbon 2600
Nickel 2646
Low Carbon 2700
Titanium 3263
Iron 2786
Chromium 3034
Tungsten 5432
Carbon 6512

I stole it from HereHere. As you can see aluminum

melts at only 1200 degrees . (After finishing this I had to make sure that cans were made

of steel, wikipedia was ambiguous about it and several other sites so I took a magnet after

some cans we have here)

Most bean cans are made of steel with an inside tin coating (After finishing the above

chart, I had to make sure that cans were made of steel, wikipedia was ambiguous about it

and several other sites. So I took a magnet after some cans we have here, it is steel). So

its melting point is Approx. 2500 degrees (high carbon steel). So the furnace produces

somewhere between 1200 and 2500 degrees Fahrenheit, because the can doesnt melt.

To make an uncontaminated melt your gonna need a better cruciblecrucible. There are quite a few ideas for building a crucible from things laying around, all available with a quick google search. :P
Heres one for exampleHeres one for example ....
lucek fjr1226 years ago
I have a similar set up and my steal can did melt. or to be more accurate the hot aluminum slowly leached through the can till I had holes.
hmm...i thought the melting point of aluminum was ~900.... o well. Great project, when i get the time, i will have to try this! =D
hi aluminum melts at 660 degrees Celsius you might be thinking of silver thats 960 degrees Celsius the chart above is in Fahrenheit
:-) thanks
hello i think i can help you with that if you would like to melt aluminum you could use a steel pot or can but stuff like copper brass bronze iron needs a ceramic crucible becuse these metals would disove the can crucible and that is realy dangerous one day i would like to put an instuctable on this subject and building a propper furnace. chhers
Tinker83 fjr1227 years ago
make your own crucibles. there's also a bunch of fun kid stuff, like science project ideas, and a couple big books of all the crazy science stuff that didn't work through history. its pretty cool if you don't already know about it.
lucek6 years ago
nice rendition. mine uses an old hair drier and some tube for air supply.
when you melt the ingot down later, it wont be free of slag. that is the oxides forming form the extremely high temps as well as simple air exposure.
HuggyBear6 years ago
Um first of all, you didn't really mention anything about your blower = ( sad face...
Second of all, like the guy below asked, the pizza sauce can will eventually start to melt/deteriorate from the high temperature. Correct me if im wrong, but if you have used it a couple of times you are probably noticing that. Just from my own personal experience, soup cans that i used as crucibles started to fall apart after like two uses.
gamerguy3146 years ago
so is this good if you just want to heat up metals too, but you put them in for less time? Also... The can doesn't get melted at all does it?(the one holding the coal)
twenglish17 years ago
nice forge, i got a suggestion you can use an air compressor instead of the blower thats what i use, it works great and higher pressure = hotter flame
the pro7 years ago
what happens if you heat up a cender block up to the temperature that melts aluminm? does it explode like river rocks in a fire (which is cool until you look down at arm and find shrades of rock and blood, not cool >:(
darkanima937 years ago
dude thanks this is a great forge and cheap too.
Bluskys7 years ago
Another source of good crucibles and crucible related information is Budget Casting Supplies:(http://www.budgetcastingsupply.com/Crucibles.php)
And with free shipping it usually works out fairly economical!
anyone know if you can have too strong of a fan? i have an old central AC fan that puts out some major thrust. would it put out the fire or would it help?
yes the fan can be too strong if there is too much air then you would get what is colled an oxidizing fire kind of the same as a cutting torch you want a reducing fire {just too little air for perfect combustion} and that olsow help to reduce the oxidation of the metal
If the fan blows too much air, it will melt the steel can. I use a blow drier (the kind used for hair) on low to melt metal. It doesn't take much air. :) stoobers@gmail.com stoobers.googlepages.com (my projects!)
You could regulate the speed with a variable transformer like a varistat or you could restrict the air going in the fan which would reduce the air flow. Have you thought about a scrap hair drier gun (lo-hi) ??
It MIGHT work, but most likely, it'll blow your coals straight out of the firepot. If you're slightly less unlucky, it'll mearly bring your coals upto a temp high enough to melt/seriously soften your tin-can crucible. Adding a hole in your ductwork, and a varible cover, you can make your own "airflow gate" to use the big fan. To give you an idea, I have used a shopvac exhaust to drive a coal powered IRON furnace. yes. MOLTEN IRON! That's probably less airflow than yoiur AC fan.
you can try you really dont want fire u want hot coals
Well I'm not sure but I don't think so,but a too big fan can blow away too much heat. Think of it as a heatsink,the faster the air goes,the cooler it is.
fjr122 (author)  shadymilkman8 years ago
Most likely, yeah. If you had a really big furnace it would work great though. :)
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