DIY Aluminium Melting

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This is how you cast aluminium on a budget and a small timescale.

Step 1: Materials

For this instructable you will need:

A large can (the bigger the better)

A 3/4 inch wood boring drill bit

A 3/4 inch pipe fitting

Plaster of Paris

Sand

A spoon

A plastic container

Scrap aluminium

Newspaper

As for the tools you need:

A reasonably hot blow torch (1000 C or above)

A drill

A vice

A good workbench

Bricks

A cheap small pan, not non-stick

Pliers

Step 2: Construction of the Furnace

Open your can, eat everything in it and then wash it

Put it in your vice and screw it so tight that you can't move it but the walls are not being crushed.

Plug in your drill and screw in the wood boring drill bit.

Drill a hole close to the top of the can.

See if the pipe fitting fits.

If it doesn't use the pliers to pry a larger one.

Mix a 50/50 mix of Plaster of Paris and sand in the container

Add water slowly until it is just viscous enough to drip off the spoon without ease.

Put the pipe fitting through the hole and block it with newspaper.

Daub the mix on to the inside of the can.

Sculpt it flat with the back of the spoon.

Daub some on around the pipe fitting on the outside of the can.

Let dry for 24 hours.

Step 3: Use of the Furnace

When using the furnace make sure you do not wear synthetics, but instead wear something like cotton, wool or for utmost safety, leather.

Surround the furnace with bricks.

Light your blowtorch and put it into the furnace.

Let it heat the furnace for about 15 minutes. Cover the top of the furnace with a brick.

Slowly feed the metal in until it reaches the level of the pipe fitting.

Pour the molten metal into the pan.

Let it cool for about 1/2 an hour, because the metal holds heat very well.

And now you have a dollop of solid aluminium!

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    9 Discussions

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    EvK5

    7 weeks ago

    Please be careful with this instructable. There is a lot of things not mentioned about casting aluminum that is important.
    I would do some research on metal casting and furnaces before attempting this. I've been casting metal for about 6 years. I have several dozen melts under my belt. I've cast from lead to brass. You can get VERY HURT OR WORSE while metal casting. I'm not trying to bash the guy but this is not something to just 'jump into'. There is a lot of safety surrounding casting.... You're melting metal at aound 1300F... Get that stuff on you and you can almost guarantee a trip to the hospital. It is a wondeful hobby but be weary of doing it on the 'cheap' and rushing through a melt. There is a correct way to do this that is also inexpensive but takes much more time than a day.

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    devilobi

    2 months ago on Introduction

    Very nice instructable i like it and if there is a picture it says a 1000 words so stop marking the instructable ad if it is a exam paper. Well done my friend

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    Daffydd

    2 months ago on Step 3

    Instructions say 'hole at the TOP of the can': Pictures show hole at the BOTTOM

    Be Careful !

    ErikaM11 3/4 inch

    1 reply
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    Why_Me_0__0Daffydd

    Reply 2 months ago

    Sorry about that. I made 2 furnaces, but with holes in different places, but with the same basic instructions. I have removed that picture, so I hope that that clears it up.

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    Gary1957

    2 months ago

    The title is casting aluminum, however it is just a melt and pour and how to make the furnace. Where is the information and example of a casting?

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    ErickaM11

    Question 2 months ago on Step 1

    What size pipe fitting did you use? Also it wasn't listed with materials although it was pictured. I love this idea.

    1 more answer
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    MipyErickaM11

    Answer 2 months ago

    The picture shows that it is a 3/4 inch steel fitting