Aluminum casting for beer lovers 🍺😀😎 Casting a classic shape aluminum bottle opener

I've already have a video where I made a key ring bottle opener. This time I've decided to make a classic style bottle opener. As usual I will make this bottle opener using lost-foam casting technology.

Casting Knuckle-Duster or meat hammer. Aluminum melting and casting

I've seen an interesting design of a meat hammer (meat tenderizer) which looks like a knuckle-duster (brass knuckles) and decided to make one. First step was to cut a pattern of a knuckle-duster using a polystyrene. During the next step I've made a mold. When aluminum was melted I poured it into the mold. The final action was to brush a knuckle-duster.

Warning: This knuckle-duster is not a weapon and has no other purpose as a kitchen equipment for preparing food.

Huge aluminum casting - 4 risers. Hanger

This lost-foam casting will be harder than usually. It'll be huge aluminum casting of a thing with a very complex shape - clothes hanger.

To make a pattern I will use polystyrene sheet. To cut the shape of hanger I'll use my new hot wire cutter.

Hollow core keychain. DIY - Casting aluminum at home

I have designed custom keychain. It'll have a hollow core and will consist of 2 parts.

Making Your Own Clamp. Lost Foam Casting. Aluminum

I didn't have a clamp for work, so decided to make aluminum one. So, lost foam casting again :)

Bottle opener. Lost foam metal casting

I wanted to make something interesting and as always useful - bottle opener. Aluminum is the best metal for casting such things.

Making a Simple Casted Aluminum Phone Rack

I've decided to make a Simple Aluminum Phone Rack. To make a pattern I glued 2 pieces of decorative plastic foam. After that I melted and casted aluminum using lost foam casting technology.

Casting an Aluminum Bald Eagle for the USA Independence Day. The Great Seal

Today, I'm continuing my video series of countries national symbols. It's 4th of July and it means the USA Independence Day. My congratulations guys! :)

In my opinion, that's my best work for now! :) I like very much how this Great Seal looks.

As I mentioned in my previous video I've decided to make national symbols from top 3 (according views) countries:

1. United States;
2. United Kingdom;
3. Canada

If it's interesting than more countries emblems will be made in the future :)

Aluminum house sign. Lost foam casting

My street was renamed, so I've decided to cast an aluminum house sign. The easiest casting technology for me is lost foam casting and that's what I like the most. For this casting I used a huge flask and a lot of aluminum. During the pouring I've got some mold damages but nothing serious.

Making a casted aluminum safe case. Part 1

I’ve decided to make a case for my camera and its accessories. I wanted it to be aluminum casted and of course safe. Therefore, it should be very durable.
I made patterns of plastic foam. The case would consist of 2 identical parts. So, I wanted to use a lost-foam casting technology.
When green sand and a flask were prepared, I started warming my metal melting furnace. First aluminum pouring failed because there was a leak on the bottom of the flask. In addition, I made several ingots. The second attempt was successful. The shape of the case part was not perfect but anyway it wasn’t a great problem. I was able to fix this. Finally, this DIY case could be used as a case for a camera, gun case, jewelry case, tool case or something else.
Aluminum casting of the second part of the case will be in the part 2 as well as case finishing.

Making a casted aluminum safe case. Part 2

This is the second part of aluminum safe case casting. I’ll make the second part of the case, sand and finish it. In the end I’ll make a short durability test to be certain that it’s really safe!
To prepare aluminum I’ll melt aluminum cans, some tubes and other scrap. The casting technology is the same as it was in the first part. It’s lost-foam casting with using a flask and green sand.
My melting furnace worked perfect and it took me less than 30 minutes to melt all the aluminum I had prepared.
Aluminum pouring was practically perfect.
The next step was to drill holes and to fix case latches and case hinges. Finally, I glued polyethylene foam to improve the case interior and thin plastic sheets to make the nice case exterior.
In addition, I tested the first defected case part to find out if it was durable. It passed the test. It didn’t get any damages after fallen of 3 meters (9.8 ft) high.

Aluminum balls lost-foam casting (using ping-pong balls)

In this video I make aluminum balls using lost-foam casting. As pattern I've decided to use ping pong balls. For me it was interesting to see if I could get nice aluminum balls in result. As channels (and frame of the construction) for aluminum I used a foam from some package.

You can watch the whole process in the video above or read step by step instruction on this link on instructables.com: Aluminum balls lost-foam casting (using ping-pong balls)

Casting Aluminum. A Saucer

Making of aluminum saucer using technology of green sand molding. To cast a saucer I will use aluminum scrap. I’ve edited this video and made it enough short because I didn’t want to repeat the whole process of production. I have several videos about melting and moulding aluminum and brass on my channel. If you’re interested in the green sand casting process in detail please watch my other DIY videos such as “Brass casting – Heavy paperweight” and “Aluminum casting – Clothes Hook”.

Production consists of such steps:
1. Making a mold using green sand and a flask;
2. Using ceramic saucer as a pattern;
3. Making a feeder, a raiser and channels to the saucer;
4. Melting and pouring the metal into the mold;
5. Taking out an aluminum saucer;
6. Cutting and sanding
Aluminum saucer is ready!

Clothes hook - aluminum casting

I needed several clothes hooks, so I decided to make one using green sand casting. I just made a flask and prepared green sand, so everything was ready for molding. I decided to use as original, one old coat hook which was made 40-50 years ago. The good thing is that it was made of aluminum and it wasn’t very hard casting.

You can watch the whole process in the video above or read step by step instruction on this link on instructables.com: Clothes hook - Aluminum Casting

Casting aluminum - Aluminum mushroom in my garden :)

I’ve made some joke (funny) video about an aluminum mushroom which I found in my garden. I didn’t plan to do such a video but when I saw that it (in fact the scrap) looked like a mushroom I decided to make it. So, that's just my installation. The most important I wanted to show was that we can use even technological material after our casting. Even scrap and fails can become a part of decoration.

You can watch the whole process in the video above or read step by step instruction on this link on instructables.com: Casting aluminum - Aluminum mushroom in my garden :)

Casting Aluminum Bars. Cement and steel mold

I prepared some scrap of aluminum, so it was time to melt it. Not long time ago, I’ve made a steel mold and several days ago a cement mold. The thing that I called “a cement mould” is a mixture of cement (45%), sand (45%) and graphite dust (10%). Therefore, I’ve decided to make 2 aluminum ingots from the scrap.

During the pouring a crack appeared in the cement mold but it didn’t effect on the bar quality. When I tried to extract the ingot, cement mold was completely destroyed. No surprises with the steel mold. It worked perfectly.

When ingots started to cool, aluminum bubbles appeared on both of them. I’m not sure why that happened. May be that was because molten aluminium started become solid but in the center it was still hot and liquid. It should be that I need to warm molds before casting though it may be not a solution of a problem.