Casting

Casting of aluminium in the flowerpot furnace

More blobs to blocks

More blobs to blocks

At the show earlier in the month I was looking for a 4 jaw chuck but failed to find anything small enough. I managed to get one online for a very good price, one of the jaws is a bit

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Terry Brown’s Shed – Casting, Maching, Projects and Gingery Shaper

Terry Brown's Shed - Casting, Maching, Projects and Gingery Shaper

Today I stumbled across a goldmine of information. Terry Brown’s shed stuff pages contain a large number of project he’s completed over the last 7 years. There’s a section on foundry work making furnaces and melting aluminium, this is complemented

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Melt 12th Oct

Melt 12th Oct

For the latest aluminium melt, I build a new two part flask and tried casting a couple of letters. After a trial run putting the sand in there was an issue with the sand falling out of the cope (the

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Building the flowerpot furnace

Building the flowerpot furnace

2020 Vision said: “Just wondering how you got the air into the flowerpot? Was it through the holes at the bottom or did you somehow cut a hole in the side? I would have thought the latter could weaken it.”

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Blobs to blocks 2

Blobs to blocks 2

From my second cast, I produced the following two blobs. The left hand one was much better than previous attempts with a large section of straight sides and a better finish. I expect the right one would have been better

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Machined blob

Machined blob

This weekend I machined up one the castings from last week’s melt. Here’s the stages from scrap to machined results. Step 1Some scrap ali that I found round the back of the shed, sawn up into suitable sized pieces to

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Red Hot – Casting

Red Hot - Casting

This morning the flower pot furnace was lit and I cast my first aluminium. I’d finally got good weather, all the safety gear and tools were finished and I’d sawn up an old strip of aluminium into small chunks to

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Furnace kit

Furnace kit

Given the price of Aluminium in large pieces and the problems with shipping I decided to build a cheap “flowerpot” / “coffeecan” furnace from scrap and cheap materials to do some simple casting which could then be machined. Everyone on

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