aluminum smelting tools and furnace

[trichrider]

i've been using my covid vacation to suss out smelting.had over a year of photos on the camera, but when i tried loading them into my 'puter the San-disc puked and destroyed all the pics.
fortunately my phone had a few back-up photos.

i began with a 55gal drum cut in half.

lined it with the outside of a bbq/smoker, then with a cardboard tube 12" diameter.
used portland cement mixed with DE (diatomaceous earth) instead of sand for the main body.
the outer circumference i filled with vermiculite.
it took some effort to align the tube entrance for the burners, but after some trial and error it was done.

i've got to look for more pics and take some more so this will be continued...

later

 

[trichrider]

...so the phone was not compatible with the 'puter. same ol' same ol' and we won't be seeing them.

here is a look down the throat of the furnace.

and some of the tools i fabricated to undertake this chore.

and here is most of my kit.

i have hundreds of pounds of aluminum cans to turn into this.

i guess i need to get a new card for the camera, since this will take awhile.

my intentions are to learn casting and these ingots are pure so a good source of material.
they would also bring a higher price at recycle centers should i not be able to use it all.

 

[flylowgethigh]

You have the basis to make ant art now.

https://www.youtube.com/watch?v=IGJ2jMZ-gaI

 

[trichrider]

i have, but that's not happening.
there are massive anthills around these parts but i respect their right to life. black ants matter!
were they the red fire ants i might reconsider. lol damn commie ants!
thanks for dropping by flylowgethigh

plan is to melt while i learn different casting methods.
i've got a few items in mind that i want to try replicating, and a few i want to design on my own.

 

[flylowgethigh]

I have commie ants, and used to have an almost unlimited supply of beer cans. Used to. BAM huh? LOL

 

[trichrider]

well now. something weird happened and i was able to recover all the pics i thought were deleted.
it must have been keeping the sandisc in my pocket for a couple days.
i'll get around to posting them sometime soon.

 

[trichrider]

i did photograph the process, except for mixing cement, and cutting to fit

innards set

lined with refractory cement and hardware cloth for something to attach the kaolwool to.

this part of the project was done, so now to make the burners.

 

[trichrider]

just five parts to each of the frosty T burners.
a .32 mig welding tip
a 3/4'' x 1'' black iron Tee
an 8'' x 3/4'' black pipe nipple
a compression fitting that the welding tip fits into and the right size for the gas hose connection
& a 3/4'' x 1'' flare fitting.

centered and drilled for the fitting and affixed with JBWeld.

added the regulator and hose for one...

...and they're both done.
didn't photo installing them into the furnace, you'll see how they attach in subsequent posts.

 

[trichrider]

this image does show how the burner nozzles sit at an angle for tornadic effect.
now for a lid.

DE and portland with a good coat of refractory cement.

and through the miracle of time emerged a completed functioning furnace.
the refractory cement had to be 'cured' by extreme heat prior to use.
unfortunately i had no tools for smelting so i had to fabricate them.
for another post...