The Foundry
Getting more into the model engine building end, I decided I need a small foundry capable of melting aluminum. It would be less expensive than buying casting, and give me something new to play with.
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After searching the internet for information and plans, I decided on Dave Gingery's design for a furnace made from a 5 gallon bucket. The plans are in Dave's book, The Charcoal Foundry.
It's amazing how hot these little furnaces can burn on charcoal. Here's a short video clip on one at full heat.
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I started with an empty 5 gallon metal bucket.
I plan to make the refractory lining 2" thick on all sides. The first thing I did was drill a hole in the side of the bucket for the air inlet. I'll use 1-7/8" ID exhaust pipe for the inlet. The pipe is about 2" on the OD, so I drill the hole in the bucket with the center 3" up from the bottom. That will allow for 2" of refractory below the bottom of the inlet.
These pictures show the pipe installed in the bucket.
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Following Gingery's plan, I made the inside form next.
The form is made from two plywood discs and a piece of thin sheet metal. The bucket is about 11" in diameter, so I made the form 7" in diameter. The sheet metal is cut to the width of the bucket, and the length is cut to the circumference of the 7" discs + 2". The top plywood disc has holes cut to allow it to be gripped for removal after the refractory is in. The lower disc will have a screw driven into it to grip for removal. The second picture shows a slot cut in from the edge. The sheet metal has a 90 degree bend 1" in from the end to fit into that slot.
With the inside form assembled the bucket is just about ready for refractory.
Now to make the lid form.
It wasn't quite as difficult as I have anticipated. I made the form out of 2" wide strips of the same sheet metal that I made the inside form from.
I made a template out of a piece of old paneling to hold it round while lacing it with wire. The wire will give the refractory a little more strength. The 3" OD tubing in the center will form the vent hole. I still need to come up with a handle or lifting plan for it before casting it with refractory.
MORE TO COME!