DIY Metal Casting Furnace - Part 1

[@SVSeeker]

Welcome home Brandon. We're glad you and your troops are home. And we appreciate the hard work and sacrifice. If you can make it to Tulsa Oklahoma, I'll be happy to buy you a meal and beers and talk submarines.

[@SVSeeker]

Thanks. Best of luck to you and your casting. We're waiting for our 4th try at a propeller blade right now.

[@SVSeeker]

Thanks for the tips. We buy sodium silicate 5 gallons at a time. It's what we used for molding the propeller blades which is why we built this furnace.

[@WagonWheels707]

Now that I'm not in Afghanistan, I've been thoroughly enjoying your youtube channel! Thank you guys so much again for the cad program. I'll be getting out in may and getting a house with a big enough shop to start building my sub when I finish the police academy! I'll try to keep y'all posted as I get started! -Brandon

[@SVSeeker]

That sounds like an great idea for a reality show. Call it Educated Cave Man. I'd like to see that.

[@SVSeeker]

It's mostly IFB or Insulated Fire Brick rated to 2600F. We used MetalCast 70 just for the top lip, vent hole and burner hole. Most of the castable was used to make the pliths.

[@SVSeeker]

We are building a 75 ft steel motorsailer, and we have cast hydraulic parts, propeller blades, rudder parts. We are still working on capstans, and have portholes, cleats, dorades, ships bell, etc, etc.

[@SVSeeker]

You must be looking at the house. We have lived in Grants, New Mexico, and Phoenix, Arizona, and Bogota Columbia. But we are currently in Tulsa Oklahoma.

[@tiredlight]

best vibrator for DIY concrete is a power sander (the oscillating one) and a piece of wood against the shell of the concrete. Works excellent. Thanks for sharing your efforts.

[@ioccatonyz1]

Best home built furnace I have seen yet. I have been tinking about building one from my 50 gal hot water heater, just lining the inside with regular brick or it would be better to just make it square out of brick and bury it on the side of a slope in a sand clay mix... anyway nice job on your furnace.

[@SVSeeker]

You can cast metal with a hole in the ground, some scrap metal, and charcoal. After that it just a matter of how much time and money you want to spend to improve the results. Either way is fun and educational. Just do some reading. We have a long page on metal casting on our web site SVSeeker under Metal Working. Casting Aluminum is the best starting point. Good Luck.

[@SVSeeker]

They are called IFB or Insulated Fire Bricks and we got our supplies from Canfield & Joseph, a local foundry supplier. Each type of IFB is rated to a specific temperature. Normal fire brick I've had did not survive 2600F. A complete list of materials is on our web site: SVSeeker (dot) com under "Metal Working", "Furnaces" Best of Luck.

[@SVSeeker]

All of my stuff came from Canfield and Joseph. They make IFB, Insulating Fire Brick for various temps. Mine are 2600F.

[@percymain2]

thanks for posting your videos! you are a great team and very humble people - you seem willing to learn and impart new skills

[@SVSeeker]

Actually I love it when someone starts with a hole in the ground, a bag of coal, and some scrap iron. But in our case while I do have a nice job as a DBA, I also have a passion for learning, building and adventure. And I allocate everything toward that passion. There is no 401K, no savings. It's all or nothing. And if we loose the boat to a storm? Well; I'll dig a hole and get a bag of coal and some scrap iron and start making something nice for Kay.

[@SVSeeker]

That's a great idea. Kay hates it when I get concrete on hers.

[@heismysail]

Glad you're home, too, Brandon.

[@SVSeeker]

@soldier715 Not sure if it will stay on the boat long, but we plan to leave with the boat only partially completed. The cargo hold at first will contain our shop, including the lathe so we can make almost hardware we need. We'll pay for the lathe and furnace with the first three parts we're working to make.

[@SVSeeker]

They are Insulated Firebricks. The foundry suppliers call them IFB. These came from Canfield and Joseph and they are rated to 2600F. You can see our web site for more details svseeker.com under Metal Working / Casting Furnaces.

[@themauip3]

Hello. Love your videos. The wife and I have watch them all, a few times. I ran across this video today of this guy making a small "coffee can furnace". The part I liked was what he use to insulate it, very DIY. I thought you might find it interesting. How to make a coffee can forge Cant wait to see the rest of the boat get built.

[@allsortsofinterests1]

Just re-watched this video and noticed the Sairset and your comment about it drying out. If you have a ceramics supply near you sodium silicate is used as a slip thinner, also the wetting agent in the mortar. you could purchase enough dry clay and a gallon for less than fifty bucks and mix it up as required. the sodium silicate was like $12.

[@googacct]

Very cool. I have been wanting to do something similar on a smaller scale with a 5 gallon bucket.. From what I have read, I thought there was supposed to be a small drain hole in the bottom in case any metal spills out or if there was a crucible failure. Looking forward to the next update.

[@SVSeeker]

The IFB are rated to 2600F but they would likely survive 3000F, and that burner will easily make 3000F. We have only cast aluminum bronze, no iron.

[@SVSeeker]

Great tip. Thanks for sharing.

[@SVSeeker]

Sure. If you are on FB, join our "SV Seeker" group and I'll keep you advised when we will be casting again. We just finished cutting two wax patterns for another try at lost wax capstans.

[@geraldestes2470]

thanks doug mr. jackson, ive used a regular palm sander with a piece of old tire on it as a concrete countertop vibrator. works very well at flowing the mix in and around the internal reinforcing.

[@SVSeeker]

I certain that regular brick will crack and fall apart if they don't explode. Digging in to a clay hill side will be messy, but it worked for the Babylonians so no reason it won't still work. Good luck.

[@bliv8282]

Furnace looks awesome. Good video, thanks!

[@SVSeeker]

Sorry, I don't know very little about titanium. I think they normally use an arc furnace and melt and pour it in a vacuum.

[@SVSeeker]

They are rated to 2600F and if that temperature is not exceeded and metal is not accidentally poured on them, and the furnace is not dropped or handled roughly, then they should last for a hundreds of firings. In the real world and expect to replace them long before they fail due to the temperature exposure. Google IFB or "Insulating firebrick" for more details. --Peace

[@SVSeeker]

Thanks. Not so sure about humble, but that's improving with the number of mistakes I make.

[@heismysail]

Thanks, Tony. Doug did do a great job with it. Hope yours turns out well, too. :)

[@arthurstacey2730]

for a vibrator for the cement you can use a jigsaw without a blade and work it all around what you cemented

[@SmithDrewSmith]

I'm from Owasso. I REALLY need to see this thing in action sometime!

[@1932cheytruck]

great videos. I have been thinking about building another larger furnace my last one was in a propane tank and all refractory (very heavy) The act you could lift the base has me sold on using a blanket this time around ...lol Question I notice on your lid the blanket doesn't look covered with anything except around the vent , did that cause you any problems ?

[@allsortsofinterests1]

also perlite and sodium silicate can be used in stead of the blanket for cost savings, although the blanket is nice!

[@Duckyistrippin]

If you go to boiler shops, they usually have out of date refractory they will just give you. The alkalinity of the mix only allows it to be stored but so long. I got a couple well expired bags of koacrete, worked a charm. its real lightweight too. Just like the K bricks ya got.

[@soldier715]

Very well done, but what exactly is the point of having the furnace on the boat?

[@paulcoulter7181]

Hey Doug if yes a saw all with out a blade it works great as a vibrator. But be careful you can over vibrate the concrete

[@Rulof_Fai.da.Te_]

perfect job! compliments!

[@arthurstacey2730]

for a vibrator you can use a palm sander and run it around the item that needs it

[@KeithFenner]

Looking Good! Is taking the furnace with you, on the boat, paranoia, about hitting the propeller and breaking it off? That only happens in the movies! :D

[@TheDarkalkymist]

had a thought, not sure if it will work or not and not all that familiar with the process but i ran across a reference to lost foam casting which uses foam as the original that gets burned out when the metal is poured

[@allenwilliams5594]

I love your video, and I would like to make one myself to melt bronze. Is the refractory cement that you used on the top and along the edges of the serablanket the sairset or is it a different material? If it's a different material, what is it and where do you get it? I love all your videos about your boat and all the other projects that you're doing.

[@heismysail]

You're welcome! Have fun building one this summer if you get it to. :)

[@PlansForTheDay]

The little boy is soo cute! Finders keepers

[@SVSeeker]

Everything including the burner was less than $1000, and it took about 3 days to put it together.

[@erynthegrey]

The best vibrator around (and you already own it) is a cordless hammer drill. 1/2" bar stock chucked in, and act like you are drilling a hole in the side of the barrel, or concrete form. Move it around the circumference. It'll vibrate all the bubbles out.

[@Brad1962Fisher]

a good vibrator for Cement pouring is a vibrating sander - just touch it against the outside of the form and watch if bubble out and level out.

[@thinkpad411]

You guys are awesome. So innovative.

[@heismysail]

Thanks for the tip! Now Doug won't have to steal mine anymore.

[@thecuddaking]

Where did you guys buy your bricks from? And what's the technical name for them because I bought fire brick from a stove place and they aren't white or lite weight at all. They're kinda tan brown and heavy made of sand looking material I guess. Thanks for info if you can?

[@jakemasheck5005]

Hi, what is the temp rating of the ceramic blanket? I love your videos. You are an inspiration to many!

[@SVSeeker]

+Jake Masheck 2300F I think. But I've seen it at 3000F it just gets stiff and brittle. ....and thanks.

[@SVSeeker]

Search "DIY Metal Casting Propane & Waste Oil Furnace Burner" It's an awesome burner.

[@gummiman01]

How big is your boat? What kind of items do you find you need to cast?

[@justencase1523]

When I pour concrete steps I vibrate the forms using a hammer drill just on hammer. I bet an hair hammer would work great on low pressure to vibrate as well.

[@gdzeek]

Do you know where I can find an in depth explaination of the blower and propane setup?

[@lol567345]

nice work ! well done

[@motton6]

Hey I have been thinking about getting into metal casting and I was wondering what type of furnace you would recommend. Should I build a furnace such as this one that has the ability to melt iron or would it be a better idea to build a furnace that can only melt the metals that have lower melting temps? I know that I won't melt iron often but kinda like the idea of having the ability to do so. What do you think?

[@SVSeeker]

+.Z Sexton I'd recommend starting with something that is just stupidly simple. Aluminum can be melted in steel pot over a stove. A flower pot furnace will go a long way after that. Once your ready for something nice, you'll know exactly what you actual need. svseeker.com/casting_furnaces.htm

[@trekranger]

where did you get fire brick and is it the same kind that jewelers use ?

[@i694u2]

what type of concrete or refractory did you use on this build ??

[@aaronwilson4294]

Would it be possible to use firebricks that are the same dimensions but rated to a higher temperature than 2600F(say the were rated to 3500F) to get higher temperatures than 3000F in the furnace and still be safe or does the propane only heat it up to 3000F no matter what temperature the fire bricks are rated at? Thanks for sharing the construction of the furnace.

[@SVSeeker]

+Aaron Wilson Absolutely. Super Dave melts cast iron with the same burner. 2600F IFB could likely work at 3000F but they will start to deform (melt) so you'll be much better off with 3000F IFB if your wanting to pour iron. And I think propane will do it, but I know diesel and oil will.

[@SVSeeker]

We've cast NiBrAl at 2100F, but the furnace is capable of 3000F.

[@SVSeeker]

@KEF791 Oh! Don't say that. I love the African Queen. :) Actually the plan is to leave without things completed and finish up once we're on the water. I doubt it's a permanent addition. Not one this big anyway.

[@noahd8673]

What is the diameter of the burner tube? you website only says it needs to be at least 2 inch but u dont say how big yours is.

[@lol567345]

btw that little boy is so cute lol, keep the good work!

[@NaturalStyleOJ]

Do you think titanium/titanium alloy would be compatable?

[@SuperLazyCoder]

Wondering what bricks you are using in this build ? So far I have found "K-26 Firebrick" but I have been looking for "JM-30 Firebrick" Wondering where you sourced yours, and what type you used ?

[@SVSeeker]

More details are on the web page. The link is in the description.

[@Tonygreens1]

what are all the materials i need to cast metal i really want to start making stuff!!!

[@17091ira0072]

could i substitute the gas for filling it with white coal, coke or charcoal? and attach an air supply at the bottom? would i still be able to get a good heat?

[@SVSeeker]

Sorry, no idea, I've not used a coal fired furnace. But many of them are around, I'm sure you will find what you seek.

[@noahd8673]

just thought i would put this out there for someone not having the bet success with a hack saw blade, an X-acto knife worked a lot better than a hacksaw blade for me

[@jiuxianghou5411]

What is the duration of those bricks? How many days can they last in the forge? lol

[@igo4rams]

Love the web site and KZbin videos. You two are good people. Always looking for updates. Lots of information, I think I have read it all but could not find anything about how you plan on moving the boat and where. Sure don't want to see the shipping bill. I don't facebook so I will look for you answer here or on your site. Could not find an email address on your site. Thanks, Ken. Oh, we love to sail and dive also look at our youtube videos.

[@qasimshammary1563]

Can this furnace melt a cast Iron or Steel Iron

[@Matzul98]

I'd like to do this kind of stuff,making a little encampment in a forest,finding resources in the world,making my own house,but I don't have this kind of materials

[@SVSeeker]

Metalcast 70, castable refractory

[@SVSeeker]

I do the same things you're doing. I attend KZbin University and ask a lot of questions.

[@Duckyistrippin]

of course lost foam casting works. but that has nothing to do with constructing a furnace. only problem with lost foam or wax casting, is you need a way to manufacture the plug. Lost whatever casting, ie investment casting, is usually reserved for smaller high detail objects. Like rings and jewelry. Though you do see bigger art pieces cast using the lost wax process.

[@Tonygreens1]

I checked out the website i really liked it thanks:)

[@silentscribes]

12:30 there is actually zinc in it , yeah the gov. rips you off. I love it.

[@daviddrinen1265]

by the way you guys did a very good job

[@daviddrinen1265]

what kind of fire brick is it. I know its soft but all I have found is the real hard brick

[@SVSeeker]

+david drinen www.ceramaterials.com/insulatingfirebrick.html

[@daviddrinen1265]

thank you .

[@gsmith128251]

How do you calculate the miter cut on the bricks to line the circumference of the barrel ?

[@SVSeeker]

Eye ball it. Set a few in, and adjust as needed. :)

[@SVSeeker]

No mask, because I considered the risk and made the decision not to. Others might play it safer. That's their choice. But I have observed over the years that safety is a slippery slope that ends up with many of it's champions living life in fear of the next thing the might harm them and they forget to live life.

[@kurkim]

what is the stuff in the cement mixer

[@gettaoo14]

good job

[@gummiman01]

your video is like many other DIY videos, only you guys can AFFORD stuff. You seem like tinkerers, only wealthy, unlike most other tinkerers. what do you guys do for a job??-asking because i might learn something.

[@TantalusWolfram]

i love it: "you think it's copper, but no, cause the government actually rips you off." good work, teaching your kid how the world works so early.

[@YogiPaolo]

brilliant!

[@jiuxianghou5411]

Thank you so much. -Peace

[@NaturalStyleOJ]

How hot can it get?

[@JeffersonianTV]

no really how do you know this stuff?

[@noahd8673]

how much did you pay for the cerablanket

[@SVSeeker]

+noah he (noahdthehorse) I do not recall. There is lots of it on eBay.

[@noahd8673]

+SV Seeker thanks for the fast reply

[@countofthenigth]

can the furnace melt Stainless steel ? like to know !

[@SVSeeker]

Not this one. Cast Iron, but not stainless. I've only seen stainless done in induction furnaces.

[@countofthenigth]

thanks for replying and thanks for your videos.

[@dalsenov]

SV Seeker Hi. Very interesting! As steel is an iron-carbon alloy,can you mix molten iron with coal in order to make steel?

[@zboy48]

how hot can this thing get?

[@SVSeeker]

Do-It-Yourself

[@aj23d]

where did you buy the sairset ?

[@SVSeeker]

+al jolly www.canfieldjoseph.com/

[@MadPyrotechnicus]

You look like the greatest dad EVER :D "Let's melt down the penny! It's got zinc in it... You think it's copper but the government rips you off!" :D xD

[@heismysail]

Yes, he is a cutie. And now he has a little sister. Can't wait to see her with hearing pro and goggles on. :)

[@Matzul98]

yeah but the resources around the world are exhausted,no more gold in caves,no more iron,I think I can find clay and make bricks and after make a mini-house