In this project, we’re using equal parts of sand and plaster to make a simple backyard foundry that’s powerful enough to melt scrap metal in seconds.
With this homemade furnace, we have the power to liquefy aluminum in the backyard and cast just about any object we can think of.
You will need some big bag of play sand and some plaster of paris both of which you can find at your local hardware store for under $20.
We are also going to need a 10 quart steel bucket and a tablecloth to cover anything.
For this makeshift refractory lining we need One and 1/3 buckets full of plaster Paris or 21 cups, One and 3/4 buckets full of sand or 21 cups and 1 and 1/4 buckets filled with water or 15 cups.
Mix everything together. It’s really important to get all the dry powder wet and work out any lumps as quickly as possible. And after mixing for a couple of minutes, it should be fairly runny and roughly all the same color.
Transfer the mix to the steel bucket upto 3 inches from top.
We use the plastic measuring bucket to form the center of the foundry.
Let the mixture dry for 3 minutes.
Next step ,we turn an old steel fire extinguisher into a custom crucible. Depressurize the tank and unscrewed the valve from the top to make it safe and easy to cut in half with a hacksaw.
At this point the plaster should be pretty well set. So let’s dump the water from the bucket then use a pair of channel locks to pull the bucket out.
Next step is make an air supply port .Using 3/8 inch hole saw and a metal cutting blade, we cut a hole to accommodate the one inch steel blower tube.
The blower tube is made of one inch steep pipe ,one inch PVC coupling and one inch PVC pipe.Threads on one half of the coupling screw onto the steel pipe and the slip adapter on the other end simply pushes onto the PVC side easily.
Next step is to build a lid to retain the heat.You need a couple of 4 inch U bolts.Make them stand upright into a 5 quart bucket filled with the insulating mix.
To relieve pressure buildup, make a vent hole using a 3 inch hole cutting saw.
This design works great for venting pressure and gives us the option to melt metal as well without even having to take the lid off the furnace.
By the way, if you run out of soda cans to melt, you could try using it as a blacksmithing forge or even a barbecue for summertime grilling.
We evenly place 5 charcoal briquettes at the bottom of the crucible made out of steel fire extinguisher, helps smelt the can faster once we fire it up.
A hair dryer is taped to a PVC pipe and inserted a couple of one inch couplings to connect the steel tub eat one end and give the blower to a quick release feature. This way it’s super easy to take apart and fits into a five gallon bucket for easy storage.
The charcoal is filled it to the top and we breathe life into the steel furnace with a propane torch.The hairdryer is set to the low setting and blow a steady stream of oxygen on the charcoal to really heat things up.
The lid we made keeps the heat inside so it conserves energy while it’s bringing up the temperature. The coolest part is that the crucible lines up perfectly with the hole in the center.
The container is three inches wide, which is the perfect size for melting standard size soda cans like these and at temperatures over 1000 degrees Fahrenheit .
In order to isolate aluminium, first we remove the crucible making sure we have got a very secure grip with our tongs and slowly pour the liquid into a steel mold.
The Soda cans are molded in the form of ingots.The purpose of an ingot is to keep some pure metal handy for when you want to make something cool.
- How to build your own DIY off grid / grid down Solar Power Back up system from scratchThis project goes over the build of a Solar Power Grid Down Backup System to generate your own alternative power.A great way to utilize renewable energy as a backup source of power. Whatever may be the reason , may be to offset electricity bills or for self reliance to provide when the grid goes down, a solar backup system is simply a great way to provide alternative power to maintain a lifestyle of reasonable convenience. If the grid should go down, I can have a freezer, power lighting, pump water, maintain communications, use tools, and charge every little device I have from flashlights to kindles. This Off grid Solar Power System is composed of 5 components. Solar panels to generate the power, a charge controller to charge the batteries, the batteries to store the energy, the inverter to provide AC to the household items you wish to power. Also you need a Kilowatt meter. The kilowatt meter measures two things you have to know how much energy your devices draw at any given moment, and how much power they consume over time. Here we use 100 watt monocrystalline panels, a 40 amp MPPT charge controller, a 1000 watt pure sine wave inverter and to store the energy, 446 volt golf cart batteries totaling 470 amp hours. First you need to size your system by figuring out how many devices you are going to want to run at the same time. This will determine the size of your inverter, the inverters function is to take DC power from the batteries and converted to AC power for use with household appliances. If I have 1000 watt inverter, this means I can run up to 1000 watts worth of devices at the same time. Once you have evaluated every device that you feel that you are going to need, should the grid go down, you are gonna have a good idea of how much power you need to generate each day. The battery bank consists of four, six volt, Duracell SLIGC 125, golf cart batteries connected in series. Golf cart batteries are designed to deliver a lower amount of power over a longer period of time and then recharge quickly. When picking a spot to locate your panels, you have to consider that the sun will be lower towards the horizon in the winter, and closer to directly overhead in the summer. Building a system that actually tracks the sun would be best as the panels are always pointed directly at the sun. Also mount your panels as close as possible to the batteries. This is because the longer your wire run, the more energy is wasted due to resistance. You also need to select the proper gauge wire to transmit the power from the solar panels to the batteries. Between the panels and the batteries is the charge controller ,it controls the charge of the batteries and make sure that the batteries get the proper voltage that they need and that they don't get overcharged. Here we use an MPPT Solar Charge controller. If your solar panels are wired in series and connected to an MPPT charge controller, the voltage adds up ,thus giving us enough voltage to charge the batteries. An MPPT charge controller can charge your batteries nearly the entire time The sun is out. If your panels are far away and you want to save money and wiring, then the MPPT charge controller is way more efficient than PWM. The first step in making your solar system safe is making sure that there's an automatic and a manual way to disconnect power in each segment of the system. Starting right here at the battery box we have a 300 amp manual switch to kill the power from the batteries to the inverter as well as a 200 amp fuse that will blow automatically. Another component to the safety is the grounding. Grounding your system is quite easy to do. So get an eight foot grounding rod and drive it into the ground. Then pick up some copper grounding wire, some lugs and connect the frames have all the panels in any metal components in the system including the charge controller and the inverter.
- DIY Video : How to build a Thermal Vacuum Water Pump that needs no electricity and has no moving parts!
- DIY Video : How to build a Survival Water Distillation System for under $5 and turn Salt Water Into Fresh WaterThis project goes into the build a simple survival water distillation system to turn your salt water into drinkable fresh water. This setup can be made with little more than two glass bottles, some metal trays and some sand. So the primary components of this setup are two glass bottles, the wider the bottles are in diameter ,the better and a pair of metal trays. The first part of this process will be to prepare an area such that the two bottles can rest mouth to mouth. The important part is that one of them needs to be suspended over a heat source. This could be done over an open campfire, you just need to find a way to suspend the bottle above the flame either using rocks or logs. Cut a small notch on one side of the pan so that the neck of the bottles can sit a little lower in the pan. This is by no means necessary, but it will make the setup a little more secure. With the trays secured in place, both of them are now filled with sand. The sand will allow the trays to more efficiently act as heat sinks, one tray to cool one of the bottles and the other tray will be used to very evenly heat the other bottle so that it doesn't shatter from being heated too much on one side. The bottle is pressed firmly into the sand so that it gets good thermal contact and will be heated evenly. The second bottle is adjusted such that its mouth will meet up with the first and it is also pressed into the sand to obtain good thermal contact. Another reason that I'm using sand for this is because it makes it very easy to adjust the bottles angles and it is best to make the bottles meet up as evenly as possible so that there is not much room for water vapor to escape. We want it all to make it into this second bottle where it can condense as freshwater. As an additional measure to keep the cold half of the bottle cold, we wet the sand on this bottle with water or cover them with a wet cloth to allow evaporative cooling to take place. With such a large quantity of sand in this tray it does take a little while for it to reach the boiling point and get this process started. But once the sand has reached that point, it stays hot for a long time. So it is a pretty quick process as the water boils dry in this first bottle to simply refill it and you can continue on with the distillation process as long as you want. Rotate the bottle so that the top portion becomes hot from the steam, it is rotated into the cold sand below. And in that way the entire bottle maintains a cold temperature which causes the distillation to go much faster. https://www.youtube.com/watch?v=R_-wFiFdwAE