The Foundry Flourishes!

Two posts in one day! I actually have several posts in draft form. The Mayan Calendar idea actually came as a dream. I am fortunate to be able to remember some of my dreams.

So the third clay foundry I have made seems to be holding together, even at 1400 + degrees. The lid didn't fare so well, as the other 2 did, it cracked to pieces. I noticed a 25 pound barbell weight laying around and it happened to fit quite well. A test firing of the foundry didn't end up well. The aluminum ended up in a big mass and it stuck in the stainless steel sugar canister I used as a crucible to melt in. I suspect the 25 pound weight "stole" too much heat from the foundry. The clay lids act as an insulator. I later found a disc brake rotor that fit as a lid and gave it it try today. Everything went nearly textbook! I have made a 5 inch steel pipe into a crucible and despite a small dribble of molten aluminum from the bottom of the vessel everything was fine. You can see the pipe with molten aluminum in the above picture. She ain't pretty but she's hot!

I used aluminum pie plates, disposable roaster pans and an old gas grill I hammered to pieces small enough to fit into the foundry. If you place large aluminum pieces over an open fire for a few minutes they break easily with a hammer. All told today I netted about 2 pounds of alloy. Probably 8 pounds short of what i will need to cast a metal lathe. looks like I have to eat more pie! I used a muffin tin for molding my ingots after I skimmed the dross from the melt.

You can see the nice shiny "biscuits" in the picture.

Considering my use of a homemade clay foundry, fueled by charcoal and a hairdryer for an added air charge and all the tools I used for skimming and pouring and capped by an old brake rotor I am extremely satisfied. Just as an addendum, I do use leather welding gloves and apron along with a face shield. This can be dangerous stuff. The heavy plank I placed the muffin tin on to pour my alloy was burned about a quarter of an inch deep and smoked for more than 20 minutes.

As a closer I have added a picture of the "Nokatay-Rat's Nest Shop" doors painted a few months ago by my nephew Justin