FIRE-KEG Foundry Furnace | Removing Forms and Curing the Refractory (Part 4)

This video documents removing the forms and curing the refractory The curing schedule calls for a very slow first firing. This allows for all of the entrapped water to find its way out.
I plan to use the CNC and the aluminum foundry as a great 1-2 punch for making cool stuff!
If you are looking for Plans, Patterns and Parts List, please go here to get the recently finished plans!
www.grunblau.co...

[@jamesevans938]

Thank you for putting the Celsius conversion much appreciated

[@1a1u0g9t4s2u]

Do not recall how I came across your series of KZbin videos on constructing a Refractory. After watching many other builds, yours is by far the best and your attention to details. Your fit and finish is leaps and bounds above all the others. While watching the other videos, I would see places for improvement. But I could not see any areas to improve your design. A base with wheels would be a nice option, but I seem to recall you have already expressed this as an option.

[@Grunblau]

Thank you. As far as room for improvement… I have considered re-editing this because I don’t know how anyone survives the music, lol!

[@GlobalRA16]

Best DIY foundry I have ever seen on KZbin. Thanks for shearing this.

[@mavos1211]

Please upload some more content, your work is second to none. I just love the precision of it all. A true craftsman.

[@MrAllan9]

Finally, someone that knows what he's doing on a professional level. There's an insulation available through your refractory dealer that prevents heat loss as well. Saves the forge, and money in propane. Thanks for sharing.

[@ChristopherJones16]

You referring to Ceramic Insulation or Fire Wool?

[@MrAllan9]

@@ChristopherJones16 Niether, it's a hard board that comes in sheets with different thickness. Most refactory suppliers sell it. I use to make smelting furnaces for melting scrap aluminum, and it made the refactory last much longer and used less gas.

[@thomasutley]

Brian, I'm itching to get my own home foundry up and running. Thanks for sharing this level of detail with us!

[@Grunblau]

Thomas Utley Absolutely! I have designed 3 different variations and after 7 years I finally just jumped in and made it. I still will need to make a base for it and possibly a ceramic blanket clam shell if I need to go for extremely high temps!

[@Gingersrevenge2]

Hello Brian, I have been collecting the supplies and was wondering how much castable refractory you ended up using, I'm sorry if i missed where, or if, you have already posted it. you are truly an inspiration to everyone who watches!

[@Hunterslife315]

Honestly i watched your video without sound and my opinion is, that this is the coolest most easiest and understandable video ive watched yet.. Simple but great work and disign u made man. And very clean work! Great outcome. Better then most videos ive watched. And im just starting a keg forge.. Ive made a few regular forges but i wanted to switch to a keg for awhile and your video was the 1st thar came up.

[@doublewideshine5410]

For those who want to do this it should be noted that refractory dust is high in silica and is very very bad for you. A dust mask is essential.

[@geoffrobert8818]

doublewide shine I did not know that good to know information

[@everettamador9885]

doublewide shine I thought so...Isn't like white sand ... Used in Sandblasting? Never have liked the stuff, used to sandblast. With coveralls and a full respiratory mask made for silica...

[@sammyd7857]

As long as you don't do it regularly it is nothing.

[@110americalovingpatriot2]

For some reason when you put the camera on the hole in the top I thought I bet thats what HELL looks like!! Nice Hellforge.. I found a full keg a couple months ago and haven't decided what to do with it but I know now. It weighs like 162 lbs but after I cut it open and let all that PBR out it wont be so heavy. Thanks for the idea and video.

[@EddieTheGrouch]

I want my furnace to grow up to be like this one! A fine build, Brian.

[@Grunblau]

+Eddie the Grouch Bah, you have seen SV Seeker's rig in person! That is what a furnace should 'grow up' to be! Thanks for the comment though! I'd like to think I'll be able to make it down there at some point...

[@itsthorondil7608]

Love the leftover 'Lets do this' from the bucket

[@tomsdreamshopworx]

A little late to the party, but wanted to say how much I enjoyed this series. I like the way you think. Consider me subscribed. Keep up the great work!

[@HaLo2FrEeEk]

I was in awe the entire time I was watching this series. The attention to detail was incredible, and the finished product was masterful. Amazing work! I'd love to build something like this myself, but money is kinda tight at the moment, so I'll have to settle for a much less refined furnace for now. Anyway, awesome job on this, you got a new sub :)

[@Grunblau]

Gather the parts over time... I had the beer keg for a over a year before starting... Odd source for brass fittings is a salvage yard. These are expensive when bought at Home Depot or Lowes, but like $1 a pound at a salvage/ metal recycler!

[@HaLo2FrEeEk]

+Brian Oltrogge Interesting. I'm in the middle of an unexpected (unwanted) move at the moment, but eventually I'll start building the stuff that I need to get into this. I used to work at a bar and I'm "friends" with the owner (as much as anyone could be with him, he's kind of a jerk). I'm not sure if they recycle their kegs or if he'd let me take/buy one off of him. Probably not, but it's wouldn't hurt to ask. As for a refractory cement, I'll probably have to go with something less refined, money just wouldn't allow for the expensive stuff, and I'm impatient. At any rate, thank you for the videos and the inspiration!

[@PressTube]

Brian, do you make these on request? I am VERY interested in buying one of these.... Maybe a collab between our channels would be great ;) Greetings PressTube (Belgium)

[@WreckDiver99]

I'm not too far from you (Chesterfield Twp). Love to see these setups. Always wanted a small furnace...and LOVE your CNC items.

[@n.barrett4734]

Oh people like this make me sick! Being all smart and methodical and safe! :) Man, you have the skills and mindset to take on any job! Well done!

[@patrickkabuki7049]

Hi Brian. Thank you for your inspiring videos. I was glad to see I can use a keg container.

[@eddie2799]

Hi Brian. Just wanted to say great job on the furnace build. Your attention to detail is awesome. I have to find some time and play with my furnace as soon as the weather breaks and upload some videos too.

[@Grunblau]

Thanks!

[@buynsell365]

GREAT Job !!! This is by for the best looking furnace I have ever seen. Looking forward to seeing what you make with it.

[@onewheeler69]

I'm glad to see other people line screws up into patterns haha Great videos

[@EFL35]

Helpful tip: If you warm up plastic with a heat gun first it will be way easier to cut. Great video though! I'll be using some of your techniques when I rebuild my foundry.

[@carlschnackel3051]

Awesome series on how to do this. Many thanks.

[@Impyman18]

Love it Brian! Your attention to detail is one of the things I love most about your projects. I'm ready to see some of the stuff you put out from the use of this bad boy. Whatcha got lined up? Also, is there anywhere else we can follow your projects for smaller more regular updates?

[@Grunblau]

***** Thanks! I try to fill in the details and make videos that I would hope to find when starting a project. The cure instructions aren't even on the refractory bag! I had to call the manufacturer. I tend to post on a couple public forums. CNCZone and AlloyAvenue, for example...

[@aussiedrifter007]

Great Video, I love beer kegs, fire and Banjos, love the music. Will be watching more of your videos.

[@JohnDoe-kp3sw]

Most professionally done.

[@WarBerJr02]

On another video, (I will find it one day,) the owner made a sculpted interior using two different plastic buckets. The effect was that the fire blasted around the base of the refractory and was concentrated at a point about 6 inches above the bottom of the refractory. I have been looking for that video for a few days now. Not that I expect, or even want you to remake your forge...

[@Grunblau]

+WarBerJr02 Someone posted a link in the comments to that effect awhile ago... I feel like that might be a bit of a gimmick, personally. I am no furnace engineer, but if I think it might be more ideal if the whole chamber was essentially the same temperature rather than really hitting a certain area. I feel like I read this some where about heating of a crucible.

[@EZRyderX]

Great work! You mini foundry is looking awesome!

[@Grunblau]

+Francois Brousseau Thanks!

[@npbwolf]

thx for all the melting points but copper what is it

[@WarBerJr02]

This is the best build that I have seen on KZbin. Why didn't you use a 35 gallon drum?

[@Grunblau]

Thanks! I wanted a stainless skin and I'd rather see a beer keg in the corner of my shop than a rusty barrel, the integrated handles are a nice feature as well!

[@BITTYBOY121]

Excellent work Brian, That is one very cool melting furnace you've made! Fantastic video! :-)

[@Grunblau]

+Joseph D thanks!

[@SteveLurvey]

What do you think the estimated weight of your setup is?

[@LordAtrix]

did you us propane all the way to 1800f, I see you swapped to your diesel/ propane burner but you don't say if you used a combination of both. would it be possible to achieve 1800f with just propane? I have a stainless steel beer keg, the walls are about 4mm think would you still recommend to add in the steel ring or would it just be personal preference? great videos, and thank you for answer my other questions. Looking forward to the dominoes box and the next subscriber plaque

[@Grunblau]

Yes, I used only propane on the curing up to 1800 F. Burning oil/diesel would have increased the temperature too rapidly. It had no trouble getting there on just propane. The little weed burner maxed out just based on how much oxygen was in the furnace due to a lack of a blower. As far as the steel ring in the keg goes... The primary reason I used them was to give a solid, uniform edge to the lid. My keg thickness was probably closer to 1.5MM or a 1/16" 4MM is pretty substantial. If you can cut it straight, it should be fine. The other reason was for a mechanical lock for the refractory in the lid... if you have the screws in there, it think that is probably enough grab.

[@markjennings2315]

Nice work. Great planning and attention to detail.

[@Grunblau]

Thanks!

[@mr.mrscreations]

very nice furnace

[@Grunblau]

Thank you!

[@DJDevon3]

What is the expected lifespan of the foundry? How to make a large enough crucible to take advantage of the large interior?

[@Grunblau]

+DJDevon3 Good question! Have 100's of melts on it now. I use a number 10 crucible but it could be larger. Imagine a Home Depot bucket because that is exactly how big it is!

[@DJDevon3]

Where is a good place to purchase crucibles from? I do not have welding capability to make my own.

[@MOONER49]

I'm no expert but what I found is a steel coupling with a steel end cap welded together works very well. For a modified Crucible that is.

[@noellaxton9780]

DJDevon3 you can order a graphite crucible online they don't have the potential to melt like homemade ones

[@DJDevon3]

Noel Laxton Finding them in large sizes is hard. Most of them are smaller than I expected.

[@ShadySadie]

Nice, do you have any documentation on how you formed before the curing? My grandfathers foundry got stolen, I would like to make another one and I just so happen to have a full size keg laying around.

[@Grunblau]

I hope you found the entire series! I also have plan sets on www.grunblau.com

[@ShadySadie]

@@Grunblau I did thank you very much

[@patrickjobling8676]

That is truly a thing of beauty..😁

[@everettamador9885]

Very ingenious...Are small cracks a normal thing though?

[@marcoboot18]

@Brian Oltrogge: at 6:12 (At 6:00pm) temperature is 1000 degrees celcius (537 degree celcius); instead of 1000 farenheid (537 degree celcius). Nice video, and well made. Hope it last!

[@Grunblau]

Yeah, I noticed that too after it was uploaded. Thanks for you comment!

[@teleman5678]

you did a great job. I wonder if you could mold some kind of expansion groove in it would it stop it from cracking ?

[@Grunblau]

+teleman5678 I think the groove would serve to contain a crack to the groove but not keep it from cracking... Plenty of people have actually cast the bore in semicircular bricks and simply stacked them! Really only aesthetic at this point. It would be easy enough to chip out the middle section when the time comes to recast.

[@johnharrington2831]

the best part is how the lid is made !!!

[@workingweekly6573]

Best tutorial on KZbin

[@dylanfraley227]

If I were to convert this to a charcoal furnace do you think I could get way with just using regular cement or maybe a plaster/sand mixture? Thanks Brian for the awesome videos and I'm looking forward for the one in the future!

[@Grunblau]

+Dylam Baker I wouldn't use regular cement. The refractory isn't that expensive... Regular cement can crack and explode. That isn't just a myth on the Internet. I was burning powdercoating off a part at the end of my driveway with a weed burner. A large chunk the size of my palm shot off and about hit me in the face...

[@Bairleafarm]

Im sure youve had plenty of use over the last 3 years - do you wish your vent was bigger or has the factory diameter been fine?

[@Grunblau]

It has been fine.... I am not sure why some people have giant vent holes.

[@Bairleafarm]

Thanks. I'm in the process of building one and dont want to cut a bigger hole if it's not needed.

[@espen990]

why didn't you simply wipe down the cement dripping down the sides, instead of having to sand it down?

[@Grunblau]

+Espen Sales By the time you have mixed and rodded a few bags of refractory, getting a rag and spending an hour chasing wet cement around the shell didn't sound like a lot of fun... Came off really easy with a wire brush. Maybe even easier dry than wet!

[@rickeymack8045]

+Brian Oltrogge have you started melting metal

[@johngalt5572]

So professional! Wonder if these things would sell. If I had the space for working with metals I would want to purchase one :) Brilliant job. If you were to sell one, how much would they go for?

[@Grunblau]

Shipping would be close to what I have in it $$ wise, lol!

[@SoCal_rnr]

that is amazing looking my friend

[@Grunblau]

+George Montes Thanks! It started out all shiny, now it looks like it has done some battle!

[@michor10]

Beautiful as always. I'm really looking forward to doing this myself. Thanks for sharing!

[@josephbeck4762]

When are you going to show how you made the crucible tongs, those are awesome.

[@Keys879]

+Joseph Beck Probably bought that thing!

[@kaighn8086]

how has this held up? has it managed to melt cast iron yet?

[@ben.d3353]

I'm making a foundry atm out of refractory bricks a beer keg and I was going to use refractory motar like you have in this vid. But I understand that motar is less durable than cement. Is your foundry still going strong or did u find that the motar started to crack? And if so, over what period of time?

[@sircarlcox]

great job on your foundry! ive built a similar one, but frankly, yours is much more polished lol. i was wondering what it is that youre using to measure the temperature of the inside? and where can i get one? I melt brass often, and it would really help to know what temperature everything is at.

[@Grunblau]

+Carl Cox For the burnout. I used a multimeter from harbor freight that came with a thermo couple. During a melt, I just watch the aluminum and as soon as the last piece melts, I give it 3 minutes in the furnace. I have a temp rod from omega, but I haven't used it yet...

[@sircarlcox]

Thanks! I'll see if I can get my hands on one of those!

[@charliescheferman]

how much refractory did you use

[@hiseminencetheholymacdiarmada]

I found 3 empty kegs in my new house and want to build one of these. How high can you get the temperature on the propane weed burner alone?

[@Grunblau]

+John McDermott Barely high enough for aluminum (maybe not). Needs additional oxygen at the upper limit...

[@hiseminencetheholymacdiarmada]

Brian Oltrogge - Ugh... I didn't want to try to build that other burner contraption you made, but I guess I will have to. Primarily I will be only melting my empty beer cans, but I would like to have the ability to go hotter if need be... Thanks!!

[@robcrawford9657]

Cool how many liter beer keg is that?

[@jeremywiste8367]

I have a feeling I would be pretty damn drunk by the time the curing process was done!

[@Grunblau]

+LC W Luckily, I mostly drink Guinness so after two I feel like I have eaten an entire loaf of bread!

[@ProDMiner]

Hey man I do not think that is just cement what is that made from? I have a propane tank I did with cement but was warned it would explode. So I took it out and just laid fire bricks in there. Then use a pipe for air and coal. I would just love something like this and to know its safer for hazardous reasons. Thanks for the video! I am subbing :)

[@Grunblau]

+ProD Miner You are correct, this is Vesuvius 3000 degree refractory cement. A big difference is that the 'aggregate' is a ceramic material as well as other materials that will actually burn out leaving air space that helps with the insulation value. Cement when rapidly heated can blow up. Refractory ceramic is more expensive, but worth it. Some people use DIY recipes but generally go with a commercial refractory for their 2nd furnace.

[@ProDMiner]

Ok thank you! I will look into getting some :)

[@popo_53]

congratulations. you replicated the weather conditions of hell.

[@jesterjunk]

Very meticulous. I love it!

[@Grunblau]

jesterjunk Thanks, I'm CNCing my first patterns now!

[@CrimHawk]

is this just a regular beer keg? I've made a small forge or of a steal bucket but I'd like to attempt this and have one that looks more presentable.

[@Grunblau]

Yup, regular stainless steel keg.

[@CrimHawk]

+Brian Oltrogge very cool. I'm looking forward to building my own now lol

[@joshrowe1554]

Where did you get your lift out tongs from? Or did you build it yourself?

[@natethetoe386]

What is the hole at he very bottom for?

[@Grunblau]

Imagine spilling a crucible in your furnace, you might like an easy way out for the molten metal. At least that was what I always thought it was for:)

[@nickpayne4740]

how much does the foundry weigh? thats a lot larger than I would need but still curious

[@Grunblau]

+YotaCrawler 4Life A lot... my guess would be about 200 lbs. I plan to make a cart for it at some point or just pick a spot for it to live permanently. Took about (4) 50 lb bags of refractory.

[@jessebrownjr]

what degrees do you keep your Bud Light Budweiser kegs at

[@omgsus]

A keg would also make for an awesome cooler. How would you do that?

[@Grunblau]

+jesusernesto24 Top of my head, same process for the keg, but use an expanding foam or cut EPS in place of the refractory. Then coat with fiberglass or plastic resin and mold in a valve at the bottom. Might be better laying on its side though, hmmm...

[@ritzbitz2000]

Just Curious, I was wondering how your keg build is holding up? Also, Would you recommend adding SS webbing into the cement for added strength? Great Videos! Thanks

[@Grunblau]

+ritzbitz2000 Holding up great! As for as the reinforcement to the refractory.... I wouldn't as it would not be unnecessary. When/if the lining in the furnace fails, I would just air chisel out the bore and go get another HD bucket!

[@mommydearest2007]

hi Brian...very nice project...my grandson is turning 21 and crazy about this stuff he made an ugly thing from instructions on another channel and its falling apart BUT IF you can make one I would buy it for 21st birthday I don`t know if you do this sort of thing but I would understand if you would not be able to make it...if you can make it I would be so greatful, please let me know what you can do...your parents must be proud.....

[@tk429]

Any info on the burner? I've got thoughts of using the same harbor freight weed burner.

[@Grunblau]

The weed burner was fine to a point. The problem is that there isn't a way to force air into the chamber.. I think it topped out about right at the temperature for melting aluminum...

[@jnuttapongj4206]

how it made casting gas burner , from Ayuttaya Thailand , thankyou

[@sergio29552]

dude what kind of cement you used and were could I buy it

[@717Fang]

What size of the keg ? thanks

[@scabble4205]

Why do you cover with black plastic bag?

[@Grunblau]

Keeping it wet longer while it cures helps to build strength.

[@tractortraumacenter1514]

this was awesome I think I'm ganna try to build one

[@Grunblau]

Glad you enjoyed it! Good luck with your build!

[@sgalien6661]

great video

[@jrmorrisjr1471]

lol'd at 01:16 "LET'S DO THIS!"

[@TomokosEnterprize]

Yer making this a doable thing friend !

[@antonimaciek2482]

6:14 not 1000 C ( 537 C) the correct description 1000 F= 537,78 C Multimeter indicates the temperature 527 C=980.6F

[@JohnDoe-kp3sw]

I noticed a lot of comments asking ? You already answered are probably not ready to take on this project

[@supernielsen1223]

Do you have a bom for this? I would love to have the drawings to so i can make one myself.. :)

[@WahedSalim]

03:08 iron man's first suit

[@tomharrell1954]

Roon Yan THATS not iron man that’s lead head

[@JoseCarlos-zb9di]

Very good.

[@motorolagarcon]

nice job !

[@gavindavies3754]

what material is the keg

[@Grunblau]

The keg is stainless steel

[@gavindavies3754]

+Brian Oltrogge ok thanks do you think a gas cylinder would be ok for a smaller one

[@XzMrtrevorzX]

if you made one of these for someone how much would you sell it for?

[@johngalt5572]

+trevor hagen I was wondering the same thing, seems like he could sell these. So many people with home-made foundries.. haven't seen a setup so nice as this guys.

[@XzMrtrevorzX]

+MGTOW FTW i would buy one also if you know any gamers send them to my channel im looking for more views and to get my channel out there

[@nelsonf982]

Home made beast 👍

[@TheDistur]

The ghost of "Let's do this."

[@robinson-foundry]

I built my furnace using these videos as a guide. Thanks! You can check it out on my channel if you are interested.

[@megadwood18]

nice job

[@Grunblau]

Thanks!

[@WillInThe04Ranger]

What is your torch set up?

[@Grunblau]

If you haven't seen it already, I did a pretty detailed video on my torch!

[@WillInThe04Ranger]

Had not seen it, Will search for it. Thanks!

[@melichyoshioamraw9333]

You can remove the bucket with a heat gun

[@tluanem]

👍👍👍

[@PavelKraus_webdesign]

Tnx for sharing! ;-)

[@tomharrell1954]

It is beautiful but it’s aluminum and I would be worried about it melting

[@Grunblau]

The keg is Stainless Steel and has been good so far for countless melts!

[@tomharrell1954]

Brian Oltrogge oh I thought it was aluminum!

[@Delimus1]

why do not you add below stones for gas fires like seramic volcanic (not coal) , It took such a long 2 hours . Nice work

[@Grunblau]

+Mustafa Delimus The burnout requires a very slow increase in temperature. This way, trapped water can slowly find its way out of the refractory rather than just turning to steam and blowing out chunks of the face. It doesn't take nearly this long to reach temp, normally. The goal is than the fire will swirl around the chamber burning up all of the fuel as it goes. The stones would just impede this action (as designed).

[@Delimus1]

Brian Oltrogge hmm oke ,drying application needs to be done once ,for To avoid cracking or explosion

[@Grunblau]

+Mustafa Delimus Yes, I think usually the aluminum is ready to pour in 20-30 minutes on propane. Now that the curing is done.

[@squrilebrain]

save some money and buy a kiln wool to go inside of the foundry

[@SamirAmmarcha]

Cracking is due to dilation,, i think

[@TractorWrangler01]

Actually it's due to slightly too much water in the refractory cement. The more water you use the more cracks you will get. That crack is not that bad actually. It's perfectly usable.

[@Anthonyrm86]

Has anyone attempted to create their own Fire-Keg? I emailed Brian about purchasing the plans on his website but no response :( I even Googled his name and "obituary" just to make sure he didn't die. He is still alive but inactive.

[@Grunblau]

Lol

[@psacentralcoast6970]

Mask on. Epicness

[@OliveDoctor]

put some little wheels on it! lol

[@Grunblau]

+Rafael Coleto Wheel patterns are cut, need to finish designing the cart!