How to Make the Simplest Metal Foundry

Introduction: How to Make the Simplest Metal Foundry

About: Crazy stuff and instructables for normal live and survive

How to make a metal foundry that works with gas. Copper melting tested! More than 1000°C(1832ºF)! This design I think is a well balanced price/resistant/workforce. Own design inspired by @thekingofrandom and burner inspired by the @ChemicalKevy

Danger!!In the video is tested using a flame but leave this method to experts because in case of leak you should be ready to blow fast and strongly or/and cut gas supply quickly. You could be serious injure if you try this method.

We will see all materials and building process on how to make a homemade mini gas metal foundry. This is the cheapest and resistant foundry you can possible make.

We try the foundry melting aluminium witch it melting point is 660,3ºC (1220,5ºF).

You will need the following material.

12L (3,17 gal) iron bucket

10 Kg (22 lbs) Refractory concrete

5 Refractory bricks

25cm (10 inch) diameter iron tube

8mm (3,15 inch) diameter iron tube Butane Repsol gas tank

Butane tank connector

Butane tube clamp

Leaf blower Crucible

Step 1: Make a 25mm Hole in the Fireproof Brick

Make a 25 mm hole in the fireproof brick. It has to make with a 30 to 45º angle.

Step 2: Cut a Brick in Half

Cut a brick in half for the button of the foundry cavity

Step 3: Make a 25 Mm Hole in the Bucket

Place the brick to find the spot to make a the hole in the bucket. First make a small hole in the bucket and then make the 25 mm hole.

Step 4: Prepare Fireproof Concrete

You can watch this two video to see how to prepare concrete. But you should use fireproof concrete.

Step 5: Wet the Bricks and the Bucket

Wet the bricks and the bucket

Step 6: Make a Concrete Basement

Make a concrete basement

Step 7: Put the Half Brick in the Basement

Put the half brick in the basement and put concrete on the corners and borders

Step 8: Mount the Brick Structure and Fill It With Concrete

Mount the brick structure and fill it with concrete. You must put first the intake tube. 25 mm steel tube

Step 9: Use a Pan or Similar to Make a Cap

Use a pan or similar to make a cap. I place a glass in the middle for the ventilation hole. Also it is a good idea to put two handles

Step 10: Flatten the Tip of a 8 Mm Iron Tube

Flatten the tip of a 8 mm iron tube to reduce the gas outtake

Step 11: Use a Screw Clamp to Attach the 8 Mm Tube to the Gas Connector

Use a screw clamp to attach the 8 mm tube to the gas connector

Step 12: Test That There Is Not Leakage

Test that there is not leakage between the iron tube and the gas pipe.

To do this, soak the junction with water and soap. Then close the pipe exit hole with your finger and open gas. If you do not see bubble making, there is no leakage. Otherwise, you need to adjust the junction.

Danger!! In the video is tested using a flame but leave this method to experts because in case of leak you should be ready to blow fast and strongly or/and cut gas supply quickly. You could be serious injure if you try this method.

Step 13: Test the Flame

Test the flame

Step 14: Wait 2 Weeks Before Using the Foundry

Wait 2 weeks before using the foundry at least

Step 15: Make Shorter the Intake Tube to 30 to 50 Cm Long

Cut the intake tube to 30 to 50 cm long

Step 16: Heat Up Slowly the Foundry But Without Extra Ventilation

Heat up slowly the foundry but without extra ventilation

Step 17: Put the Blower and Make Your First Casting!

Put the blower and make your first casting!

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    3 years ago on Step 4

    This and others like it would Great and Easier to make if it was NOT in METRIC!!
    I don't use Metric & Don't understand it. Can you put both Measurements in your
    Plans for the rest of us???


    Reply 3 years ago

    With authors from around the world, I think it's great that they share what they're doing in whatever format they are comfortable with. Sometimes readers from non-US countries complain to me because I share in standard format . . so there's no winning I guess! ; )

    If specific measurements are a barrier, there are many online metric converters that can be helpful, like:


    Reply 3 years ago

    It can also be done by hand, 1"- 25.4 mm. so 50 mm makes 1" rest 24.6mm .4 mm = about 1/64" so the rest is 63/64" If you understand Imperial than this should be a relative simple calculation, that is for most projects like the one we are looking at. for accurate projects like machinery this is of course another matter.


    Reply 3 years ago

    I have added the measurements in US metrics on the description. I hope you find it helpful. I will take it in consideration for future productions.


    3 years ago

    You did a great job on this! I would have to caution you on your method of testing gas leaks though. Why would you use an open flame to see if you have a gas leak? Standard testing method for gas leaks is soap. What you did is quite dangerous and can get someone injured by following your method.


    Reply 3 years ago

    Thank Jason for your feedback! I didn't thought than someone inexpert working with gas may not know how to react in case of leakage flame. I have added a warning at the beginning and also on "Step 12: Test That There Is Not Leakage". Now, it is also explained how to do it safely.