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
A plastic container
As for the tools you need:
A reasonably hot blow torch (1000 C or above)
A good workbench
A cheap small pan, not non-stick
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!