Hell fuel for melting Iron. Charcoal, coal and coke. More than 1500 degrees Celcius (2732 °F)

I'm going to use special hell fuel for melting iron. The main reason of doing this is really high iron melting point. Therefore, I'll mix charcoal, coal and coke to get the highest possible temperature. I hope to reach 1500 °C (2732 °F).

Where to get some copper? Starter, wires and hot smelter

Where to get some copper? That's a good question especially if you need it for free 🙂. I've found automobile starter and some wires. We'll see how much copper it's possible to get.

Hot wire cutter - my building guide

To make a pattern for lost-foam casting an essential tool is hot wire cutter. I've decided to make a building guide to show how I've made mine.

Bentonite Green Sand recipe. Sticky, oily and just great

This is a video about my new green sand mixture. This one consists of 87% of sand and 13% of bentonite clay. And some water of course :) I think in some way it's little better than my last green sand formula which consist brown clay. Bentonite clay is very sticky and oily. It's very different from brown clay. And this time green sand is really green! :)

Finally got a graphite crucible. Made a lifter and pourer

I've finally got a graphite crucible from ebay. :) It's not very expensive. A price is just $ 27 for 6 kg crucible. It'll be much easier to melt copper now.

Making a Stainless Steel Crucible and my Crucibles Collection Review

I have 2 carbon steel crucibles and 1 bigger stainless steel crucible. This time I've decided to make one more big stainless steel crucible. It'll be the biggest in my collection. Stainless steel sustains higher temperature than carbon steel.

Huge Flask for Green Sand Casting (DIY)

I'm planning several melting and casting projects where I'll need to use a big flask for green sand casting. My current flask is too small for such stuff. Therefore, this time I'll make a huge flask.

Making Charcoal at Home. Free DIY Fuel

Charcoal is a main fuel for my metal melting furnace. In this video I'll show how I usually make it.

You can watch the whole process in the video above or read step by step instruction on this link on instructables.com: Making Charcoal at Home. Free DIY Fuel 

Metal melting furnace from a scrap - building guide

First of all, I took old steel bucket which was used as a garbage can. I made a hole for the pipe which should supply the air to the furnace. After that I made ventilation holes near the center of the pot lid which will cover our furnace. It will help gases to circulate...

You can watch the whole process in the video above or read step by step instruction on this link on instructables.com:  Metal melting furnace from a scrap

How to make a crucible

In this short review I want to share my experience in making steel crucibles. I've made 2 different crucibles. First one is very simple and I practicaly didn't use any tools, the second one is more complex.

You can watch the whole process in the video above or read step by step instruction on this link on instructables.com: How to make a crucible

New blowpipe - metal melting furnace upgrade

This time I'd like to show you how I made a new blowpipe for my metal melting furnace. The reason why I’ve decided to do this is that my old ½ inches pipe didn’t allow to supply enough air to smelting furnace. I could get enough air and as a result temperature for melting aluminum but for brass it still wasn’t enough.

You can watch the whole process in the video above or read step by step instruction on this link on instructables.com: New blowpipe - metal melting furnace upgrade

How to make a flask for green sand casting

I’ve got some experience in melting metals such as aluminum and brass, so it was a time to try myself into casting. The only issue was where to pour liquid metal and how to make a form. The simplest way to make it was using green sand.

Although it should be the best way for casting, it demanded to make a flask.

Flask is a frame for the mould. It keeps all green sand inside. It consists of two parts:

1. Upper part is called a cope;

2. Under part is called a drag

To make a flask we need one long or several short planks. I decided to make a flask approx. 29 cm (11.5”) long, 25 cm (10”) wide and 10 cm (4”) high (2 parts x 5cm).

You can watch the whole process in the video above or read step by step instruction on this link on instructables.com: How to make a flask for green sand casting

Green sand formula - how to make molding sand

To make green sand or like it also called molding sand (foundry sand) we need 3 ingredients: sand, clay and water.

You can watch the whole process in the video above or read step by step instruction on this link on instructables.com: Green Sand Formula - How to Make Molding Sand

How to Make a Steel Mold for Molten Metals

Some time ago I’ve made a small steel mold for casting ingots and now decided to make a second one. This one will be much bigger. When it’s ready it will be possible to cast lead, aluminum, brass, bronze and copper. Such steel molds...

You can watch the whole process in the video above or read step by step instruction on this link on instructables.com: How to Make a Steel Mold for Molten Metals

Smelting Furnace. Project "Big Smelter". Making Outer Skin - Part 1 of 3

I have some experience in making metal melting furnaces. That’s my second project where I construct the smelter which will be much bigger than my first one. That’s why I called this project “Big Smelter”.

You can watch the whole process in the video above or read step by step instruction on this link on instructables.com: Smelting Furnace. Project "Big Smelter". Making Outer Skin - Part 1 of 3

Big Smelter project. Making the Lid - Part 2 of 3

I’m continuing building new metal melting furnace. That’s the second part of “Big Smelter” project and this time I’ll make the lid.
Last time I cut off the top of the stove. Now it’s time to make a lid.
The whole process consist of:
1. I had to patch a hole which was left from a smoke duct.
2. It was important to make a vent hole in the center of the lid for gas exhausting. I’ve made it using a drill and a cold chisel. I had to spend hours before the work was done.
3. To prepare the lid for lining with refractories I started to make reinforcement. Using bolts and pieces of wire, I welded the construction, which looked like a spider’s web.
4. Using steel rod I made two handles and welded them.
In the last part, I’ll make lining with refractory, dry and finally test the furnace.

You can watch the whole process in the video above or read step by step instruction on this link on instructables.com: Big Smelter project. Making the Lid - Part 2 of 3

Big Smelter project. Smelting Furnace Lining, Drying,Testing - Part 3 of 3

This is the last part of Big Smelter project. I’ll finish this metal melting furnace by making refractory lining, drying, firing and finally testing. I can say that it’s my longest DIY project. It took me little more than 5 weeks to finish this work. I tested it by melting aluminum, brass and copper. The furnace passed all tests and got just minor damages.

You can watch the whole process in the video above or read step by step instruction on this link on instructables.com: Big Smelter project.  Smelting Furnace Lining, Drying,Testing - Part 3 of 3