Ingots are blocks of pure aluminum that can be remelted easily.
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Step 1: Equipment Needed for Smelting.
First you need your safety equipment. "Safety First" Eye protection, Leather Gloves ( Temperatures getting past 1240 degrees Fahrenheit your hand will need them.), Long sleeve shirt and pants.(Ember do sometimes fly out of the Furness, along with it getting very hot.), and a pair of shoes(foot protection).
Next you need is a Furnace. this is something that you put your wood, charcoal, coal or heating material in with the crucible. The crucible is where you put your aluminum to be melted. It doesn't have to have the cement or plaster lining the inside but this helps make it hotter and last longer. It also needs to have a hole in weather the bottom or the side at the bottom for your air source.
Air source: I use a shop vac with the hose so it blows. you can also use a hair drier. A PVC pipe can be added to the end so it doesn't melt.
Fire starter: matches lighter...etc
Tools: You'll need a way to pull the Crucible such as pliers and a way to scrape the slag off the aluminum.
Oh if you missed it wood charcoal, or coal.
Water or fire extinguishing system.
Step 2: Set Up
Choose safe area.
Put crucible in Furness with burning source (wood).
Put air source blowing into the hole on lower part of Furness. Put aluminum in crucible. Light wood, and wait for good fire before turning on air. Wait for aluminum to melt.
Step 3: Slag Removal
Using tool, remove all the lumpy slag from the aluminum.
Add baking powder and mix to remove air and trapped gases that may cause air holes in metal later.
Add low salt to make the aluminum more fluid.
Step 4: Pour Into Ingots
Pour into cupcake pan for small ingots or into mold to make things. My next instructions will tell how to make green sand molds and loose sand molds. Add water to cool down faster. (WARNING): Cracks may occur when adding water and cooling metal quickly. Ingots are ok but parts you may want to cool over time.