Metal Casting Zone

I've got some perlite, it's really some old castable refractry I picked up. It's lost all it's binding ability so I'm going to mix some fireclay with it and see if I can mold some bricks HHWC had a cool brick mold on BYMC. I'll see if I can find a link to it.

Great I just blew $$ on portland ... not to mention shed space. (And that's priceless)

I spent the $40 for a bag of 3200 F. refractory for the hotface. I backed it up with Kaowool in one furnace and Fireclay/foam bead mix in the other,

So Jammer, where did you buy 3200 F refractory for $40? ... and how much is in a bag.
The idea of only getting 20 melts out of my furnace isn't very encouraging.

I broke into his webshots album, Sorry HHWC. I think his original idea was to pull the wires for some insulating voids. I just liked the pattern and may put some wires in for strength. Also he made it adjustable to make different sizes. Thanks H!!

inlinethumb19.webshots.com/43602/2955637620099174295S425x425Q85.jpg
inlinethumb53.webshots.com/45300/2654003560099174295S425x425Q85.jpg
inlinethumb29.webshots.com/41628/2642210000099174295S600x600Q85.jpg

The Refractory cement. Heatcrete 32
I picked it up in Canton, Ohio. It was 2 years ago so I don't know what the price is now, and that was right after a big price increase. I would like to get a couple more bags. I really like this Mt Savage, it's easy to work with, if you can find someone that carries it near you. Check Yellowbook or the Thompsons site under refractory supplies. I think the bags were 55 pounds.

Meiser Refractory Products Inc.
1250 Bedford Ave Sw
Canton, OH 44710

(330) 454-2414

www.mtsavage.com

Harbison-Walker has about the same stuff, there are a couple sellers in Charlotte NC
www.hwr.com/

hhwc is a member here but hasnt posted for ages (hhwc3) a review of his popcorn can furnace may be helpful
www.metalcastingzone.com/metal-casting-forum/casting-furnaces/hhwc-s-popcorn-tin-furnace#618

Firestix, go ahead and do the sand fire clay pearlite mix, I know 20 burns does not seem like alot before you have to do some maintence but im not talking about relineing the whole furnace. use your furncae until you lose a 1/2" of material then apply the commercial refractory as a hot face. this will save you big bucks not useing the commercial stuff thru and thru. All furnaces will need some maintence especially when going for hi temps.

Great! I plan to get started soon and take plenty of pictures! I'm sure it will provide great fodder for critiquing and comic relief. My main problem is that I don't have any aluminum to melt. And even if I did, I'm not sure on what to cast/make.

...Any ideas? Something handy and useful would be great.

There has to be something laying around the house to melt, old computers are a good source of al. heck just get some 83 or newer pennies they are zinc and very pure zinc at that. If you can get the tem up to melt the 82 or older pennies (they are copper) then you can make your own brass. hit a auto shop and ask for some old wheel weights they are tin and lead. between all these item you can make nome nice casting alloys.

Hey I forgot to ask, did you get your furnace built? and how big have/are you building?
For a first project just cast some "art" like a geometric shape. once you have done that you next assigned project is a cnc router or mill. Might sound difficult but it just a variation of a theme.

OK ... Maybe I can find some material to melt. But I'm still stuck on what to make.
Although I'm also into soap making and I need a good soap cutter. Any ideas if you think casting one of these would make a good first project?

or this one

Start simple. Maybe cast just a block first to get a handle on the whole mold making process. Just find something around the house that has a nice parting line to it and next try a mold that needs some coping down. Fart around with things for a while to get a handle on it. One thing that would be good to cast first is some sort of rammer for your sand molds, you can just make up one out of styrofoam, pack it in greensand and cast it up. Then you have actually made a useful tool as well as learning a new casting method. Get creative, and remember, you never have a failed casting, you just made a fancy ingot.