How to recycle scrap metal in the backyard by building a simple Mini Metal Foundry from start to finish

    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.



    RECENT POSTS YOU MIGHT LIKE
    • DIY Video : How to Generate FREE POWER by building a Homemade Waterwheel Microhydro System from Start to Finish
      This Video Series shows step by step on How you can provide enough electricity for one house by building a Micro Hydro water wheel electric generator .Not only you will no longer dependent on the power grid, but you’ll have electricity when SHTF and more important: absolutely FREE.Unlike solar panels, a water wheel electric generator can produce electricity 24/7.Simply,the flowing, dropping water is spinning a wheel .The wheel shaft it’s connected to a simple coil generator that produces electricity. If you don’t need electricity you may adapt the water wheel to grind grain, to cut wood, strengthen iron or to sharpen tools. Anyway you choose to use it, a water wheel is an important installation when living off the grid or when SHTF.

      Watch the DIY  Waterwheel Micro hydro System Build Videos

    • How to build a Homemade Wooden Bandsaw Mill from Scratch.Step by step build Instructions
      This project goes over the build of a simple Homemade Bandsaw mill that can that turn hard maple into smaller lumber . The first step is to make the wheels of the mill. Here we use a three quarter MDF board to make this. The wheel size is 16 inch. We use a beam compass to cut circles and cut two wheels out of them. We make a seven and half pulley for the wheel using a three quarter inch plywood and drill a five eighth inch hole into the middle where the shaft goes. We take some hot melt glue and glue the stock collar onto the pulley and tighten it with a set screw so as to stop it from spinning. Before joining the wheel and pulley together, we make another small disc to go in between to act as a spacer .We glue the pulley to this spacer and from spacer to the wheel. Two wheel bearing blocks are bolted to the wheel on both sides using 4 three eighth inch threaded rods. Make sure that the threaded rods are tight inside the hole in the wheel, but the bearing blocks itself can move around. One way to keep these bearing blocks in place so that they dont move side to side is to apply some construction adhesive to the corners. Next step is building the frame for the saw from salvaged 2 X 4 boards. Make sure that the 2X 4's are straight. Take the bench hand plane and smoothen the edges so that the boards sit flat. It takes several shallow passes flipping the woods each time to get rid of all the twists and warps. Two frames pieces hold the wheel in ,the stationary drive wheel is placed eight and half inches from the end. Two five eighth inch holes are drilled on both the frames so that axles fits in there neatly. On the other side, one holes are drilled that gives the room to adjust the wheel. We also make an adjustment collar out of plywood that is bolted into the frame and the shaft . The collar can be moved to adjust the wheel. We also place couple of pieces across the frame and secure them tight so that the supporting boards are locked in position. On the other side we install the front wheel or top wheel. This wheel needs to move back and forth to put tension on the blade. It also must have a tracking mechanism. For that we make a two small piece that locks into the shaft on the front wheel and slides back and fourth. A guide piece is drilled onto to this piece . A one inch hole is drilled into our slider piece and a three eighth inch threaded rod is secured in there with a nut and washer. These rods help put tension on the blade and also adjusts tracking. Before putting the blades on the wheels, we put silicone caulking on the wheels to smoothen it out .These have advantage over bicycle inner tubes as it doesn't drape down over. The legs are attached to the frame using gusset blocks. To put the motor onto the frame , we take a melamine board and screw them aside the stationary wheel using a cross board. This piece of melamine not only supports the motor, it also helps to brace up the top to keep that from rocking. Secure them tight so that it resists moving while the cutting is going on. Next we make blade guides near the bottom to make a guard for the blades just in case it snaps and flies off. The blade guides are made of small piece of steel angle that is glued to a ceramic piece. The way blade guides work is that they don't actually touch the blade when it is running. It is only when the blade tries to move up or down that it will constrain it and keep it on track and prevent it from twisting. A thrust bearing made of regular size ball bearings is bolted onto an aluminum angle that is further attached to the blade guide. We make a dolly cart out of 2 X 4 boards and some castors to place the big maple logs and move it effortlessly through the blades . The castors are screwed in the ends using quarter inch holes. The castors are fixed in such a way that it moves only in one direction back and forth. https://www.youtube.com/watch?v=rhFEVf8zZkg&list=PLQl9KPrpiIH9Sk0wEiN9d0ANUOK-ntV-i
    • DIY Video : How to build a Thermal siphoning rocket stove for an off grid water system. Clean and efficient burn
      This Video shows the build of a Thermal siphoning rocket stove for an off grid water system. The advantage of the rocket stove is a clean and efficient burn. This system uses 5 metres of 20mm annealed copper pipe, and though I designed the rocket in a J configuration, it worked better as a batch box. There is a vortex generator at the base of the riser and basically I was able to heat 200 litres of cool water straight out of the tap to 67 degrees Celcius / 152.7 F in 1.5 hrs.

      Watch the DIY Thermal siphoning rocket stove build Video