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How to make a simple backyard foundry for less than $20, for melting pop cans, and casting aluminum.
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WARNING:
Charcoal foundries can reach temperatures in excess of 1,000ºC, which is well above the melting point of hobbyists. This project should only be attempted with adequate knowledge and training, proper protective safety gear, and in a fire resistant area with adequate ventilation. The sparks flying from the foundry can ignite fires, and the fumes from burning dross can be toxic. Use caution and common sense. Use of this video content is at your own risk.
Music By: Scott & Brendo (“Feel It” – Instrumental) https://bit.ly/ScottBrendoiTunes
Project Inspired By:
This foundry is an original design, which comes after months of experimenting, and over 10 different prototypes. The functionality is founded on ideas I collected while searching the internet for different furnace designs.
Project History & More Info:
For this project I experimented with 10 different prototypes, to develop a reusable backyard foundry that melts aluminum soda cans easily and safely. I tested different refractory recipes, different containers, different setting for blowing air, and different types of makeshift crucibles.
I tried various ratios of portland cement, sand, perlite, plaster of paris, water, and even kitty litter. For containers, I experimented with clay pots, plastic buckets, no container, cinderblocks, and a galvanized steel pail.
I ended up favoring the galvanized steel pail, and a mix of 50% plaster of paris, and 50% play sand, by volume, which was inspired by a video by NightHawkInLight “How to Make a Soup Can Forge” https://bit.ly/IBSoupCanForge
Depending on where you get, or find, your materials the cost can range anywhere from $5-$25 per unit. With the materials I used, I was able to make 2 units for under $40 ($20 each). Even on the high end, this is probably one of the cheapest, reliable, backyard foundries that can be made.
I used mine to melt soda cans, and extract the aluminum for future metal casting projects. All the soda cans came from a local recycling depot. I bought back 30 lbs from the depot to avoid having to drink gallons and gallons of soda. 
I stored the ingots in various forms, which you can see in the video”Melting Cans With The Mini Metal Foundry” https://goo.gl/pTP1uG
The technique for making the sword in that video, and the gun in this video is called “Lost Foam Casting” and will be demonstrated in a future project video.
This rain cap has quite a bit of creosote on it. It also has an opening that lets water in. This Z Flex chimney liner also has quite a bit of creosote at the top. We are using a customized power sweep with flexible cleaning rods to clean all this. The benefit of using this custom equipment is that there is less chance of damage to the liner, and it doesn’t get stuck like regular cleaning brushes. To maintain a chimney, it needs to be swept once a year or more if you burn wet wood. If you don’t clean it often enough, performance slows down, and there is increased danger of a chimney fire.
Dean Brandhagen Chimney Services https://flue.guru
WETT Certified Wood heat professional, Red Seal Journeyman Bricklayer
Journeyman Bricklayer and Carpenter with 40 years Hands on Trade and Contracting Experience, Certified WETT Chimney, Wood stove and Fireplace Inspections for insurance and mortgage loans, Repairs and Installations. Woodburning Systems Adviser – Consultations and Inspections Chimney Sweep and Chimney Consultations, Inspections and Installations Wood Burning System Inspections, Installations, Repairs and Restorations
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Closed Captioning and Description Editing by Kris Brandhagen. brandhagen@gmail.com