How To Make The Mini Metal Foundry

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.

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.

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.

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.
#tkor #thekingofrandom

[SaintBrokenDay]

All these years later and i still remember all the steps as he lists them off, i always wanted to make this but never did cause i was like 12, but i will always remember him and his projects, he will always be the true King Of Random

[cyberdrone]

It's incredible how this video just popped up in my recommendations after all these years. I remember watching it when it first came out, and it inspired me to want to build something similar with my dad. Your influence on the whole DIY community on YouTube was truly amazing. Rest in peace, man.

[visper]

First video I watched of you RIP legend

[oofiqu]

He truly made my childhood entertaining. Rest in peace

[TheKingofRandom]

Hundreds of you have been asking for the tutorial, and here it is as promised.  I'm still using mine frequently and must have melted thousands of soda cans by now :) Some people are asking for a tutorial on how to make the sword, so I'm putting that one on the list for the near future ;)

[Peri-M]

One of my favorite videos. My condolences go out to his wife and kids. Rest in Peace man.

[joec]

Still breaks my heart every time I'm forced to remember 💔. It might sound cheesy but I doubt he ever realized just how much his simple, entertaining, and exciting videos worked to inspire the next generation of scientific minds by showing them how ANYONE with a bit of time, effort, and willingness to learn can use ordinary stuff around the house to make something extraordinary and useful

[tulkasastaldo]

I'm watching this for about the tenth time but this time i'm siting next to all the materials ready to make this forge Finally !!!!

[kuykendallwebfamily]

Just made one today, all this afternoon. While the cost of everything was actually like $100 for me since I was completely unprepared tool-wise, it worked amazingly and was surprisingly easy to make :)

[waste]

First video I watched from him and actually made this with my dad.. rip brotha

[meabn]

Love it. Made it. I did not bother with the pvc and just connected a hair dryer to the metal tube. I used the exact same measurements, you nailed it! Everyone who wants to repeat your success and has ZERO experience needs to follow your steps. I used a concrete mixer attachment on my drill and the mix came out great and gave me more time to form it before it set. Awesome video!

[badasshippo]

Long live the king of random. Rest In Peace

[sammerrill]

I first watched this video five years ago. Wow. That’s hard to believe. I’ve watched it dozens of times since then and I have finally made it. Grant you’ve been gone for a while now and my love goes out to you wherever you’ve found yourself in this stage of existence.

[mikenash]

You guys have truly inspired me to start a hobby. I build my own foundry yesterday using the steel wool to reinforce. I melted down some scrap cans and other aluminium tonight to cast my first muffin ingots. This thing is a blast.

[TheKingofRandom]

Common materials in the Mini Metal Foundry

[MrXenolich]

After several years of procrastinating i finally got around to making this yesterday. I picked up a leaf blower for 10$ and used an old propane canister for my crucible. The leaf blower ended up being way too powerful so i rigged up a dimmer switch to an extension cord to tone it down some. Works awesome, love the tutorials, keep the videos coming.

[coderedskyrim]

One of the first videos I ever watched, it is with immense dismay and sorrow that I say goodbye to this absolute legend, but I will leave you with one of my favorite quotes; "don't cry because it's over. Smile because it happened." -Dr Seuss

[bobbysmith]

Watching the first video I ever watched from him after his death. RIP

[robertlewis]

I took on this project today! It was a lot of work, but I was able to do it on the second try. My one suggestion is to pour the sand in the mixing bucket first, and then pour the Plaster of Paris. I had a lot of trouble evenly mixing the two ingredients when I did it the opposite way, and it ended up solidifying in the mixing pot before I could pour it. Overall, it was a lot of fun, and I look forward to using it. Thank you!

[taow]

Awesome!
The way that you formed the plaster and sand lining was a really good idea and i love the addition of the lid!
I need to make a new forge and my 5kg bucket of plaster of pairs arrived from ebay today!
Cant wait to give this a go once the weather gets better. 
Also I don't know about your forge but after using mine it always stinks of sulfur. couldn't possibly use it as a plant pot!