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I have the same concerns about melting. I have never been able to tell when aluminum was approaching melting point. To me it looks the same as it heats up. Same, same, same, same, same, OOPS! It's glop! If you have a heating procedure that will never go too high, stick with it.
Love your pictures. That's the way things look to me, too, after a few shots of 'shine.
Instead of styrofoam for drill bit holders, I recommend low-density polyethylene foam (LDPE). It is easy to work, but tough; it does not crumble or flake away like styrofoam does. LDPE foam makes great tool holders. Good for decades. Often found as shaped packing filler for products and equipment.
Car Door Warning Color
Yet Another Bicycle Repair Stand
Colonic Irrigation Board
Nice project. I really like reusing, re-purposing, old equipment. And it looks like you have a beautiful wooden floor. I envy you.
First time I ever saw a pentagonal snowflake! Definitely something special.
Probably excellent for flocking.
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