How to Make a Fire Brick Foundry Furnace, Part 3: DIY Sheet Metal Foundry Enclosure

Today, i build the shell for the furnace. Many people start a furnace with a stainless keg, or a bucket. I built the furnace WITHOUT an enclosure. Why? Because i lack planning skills. But I don't lack sheet metal, so I took my chinesium harbor freight excuse for a metal brake, and i set to work making an enclosure.
The results look much, MUCH more like something out of Mad Max than I had anticipated, but that's a good thing I suppose. No movie with that many superchargers can possibly be bad. I feel like i'm a bit off topic here...
Part 1 (shaping the bricks) is here: • How to Make a Fire Bri...
Part 2 (mortar and coating) is : • How to Make a Fire Bri...
Part 3: • brickfurnace4
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Janesville, WI 53545-9998
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Music: "Quirky Dog" by Kevin MacLeod. incompetech.com/
#foundry #metalcasting #forge

[@PaulsGarage]

The welder I used: amzn.to/3YSpoKK close enough anyway, mine was replaced by that one

[@matthewwheelock4319]

Dude that is the best DIY furnace I have seen on KZbin. It looks like a castle or a fort....... FORT FURNACE OF GARAGE

[@PaulsGarage]

Thanks! I'm not sure it qualifies for "best" yet, though, it hasn't melted anything yet!

[@nrwl23]

I don't know why but your quips and sense of humor cracks me up at every turn. I'm enjoying the videos for learning and engineering (or not) reasons, but I appreciate the attitude too. Thanks. OMG the grunts...heghigeeeeettt. Wow. Maybe I'm punchy at work.

[@PaulsGarage]

thanks! glad you enjoy!

[@NormReitzel]

When I worked for phone company (aka the evil empire) I would come home completely stressed out and fatigued. My wife started doing ceramics, so I started throwing pots on a home-built kick wheel. Then I needed a kiln. So I built one, then another, then another... Five in total before I had something I considered "operational" So, brick work not perfect? Yeah, that's how it works. Good job, nice explanations.

[@danieln9044]

I have to say, I've been binge watching your videos for a while now and you are hands down the most entertaining and comedic KZbinr I've seen in a long time. You never fail to make me laugh with your stories and amazing metal bending sounds. I look forward to every Friday when you upload. Keep up the amazing work!!

[@PaulsGarage]

+Daniel Nelson thanks! I’m glad you like the videos!

[@The_Goto-Soto_Nippon]

This is Exactly what I was looking for!

[@mikecurley2072]

I need to start wearing blazer in my work shop. It just looks cool.

[@joegarcia2969]

love his shop coat...great video bud

[@bigstackD]

Laughed every time you bent the metal in the vice😂🤣. So professional Paul 👍🏻👏🏻.

[@PaulsGarage]

+bigstackD Casting those are the proper professional metal bending sounds, right? :D

[@1pcfred]

What is wrong with bending things in vises?

[@bigstackD]

Paul Frederick the noises Paul was making cracked me up😁

[@1pcfred]

oh

[@jacquesbouchard8884]

Oh man !!! These sounds while folding the metal is sooo funny !!! I do them without thinking !!! 😂🤣😂🤣

[@lancasterfreepress9219]

After watching several of your videos I would suggest you should always start with plan B since plan A seems not to work a lot of the time. LOL. Love your delivery and methodology of your problem solving. It reminds me of a basic cable how to program someone made in their garage. Keep it up.

[@redbeard8689]

Watched every step of this process and SERIOUSLY looking forward to seeing it in action!

[@PaulsGarage]

me too! thanks for watching

[@fiveletters]

Wait! You have a rotary? I mean, of course you do, they're cool! Been watching your whole channel over the last few weeks and really appreciate you sharing your experiences!

[@PaulsGarage]

Yes! Thank you!

[@markkeating2941]

Very entertaining - and informative! Less pop up heckling.

[@robertcloe2140]

I love the rapid fire hammering 🔨

[@PaulsGarage]

Who needs a power hammer when you can just edit it faster? :D

[@nbrunojunior]

Man you are crazy, that's why I watch your videos. You bending those metal sheets without wearing gloves is just insane.

[@PaulsGarage]

it might not surprise you but i've cut myself multiple times. Never deep enough to cause gushing blood, though. I try to be careful. Wearing gloves has downsides, like lack of feeling and control. Also, the gloves are on the hook waaaaay over there, and i'm not going to walk 10 steps over there to get them.

[@nilsg9199]

Paul, I love your videos and the fact that you tinker in a tweed sport jacket. Keep it classy!

[@PaulsGarage]

Classy indeed! Also wool is flame resistant and wont melt with heat, so thats handy

[@nilsg9199]

Beats a nice double-knit polyester any day of the week!

[@442jetmech]

Is it bad I find myself hoping he gets to plan D or beyond? It's just so entertaining, but also helpful as I'm trying to build my own furnace.

[@rebeccaking2584]

that was awesome. Love the sound effects when you bent the steel. Thanks for the good laughs.

[@PaulsGarage]

Thanks! Glad you liked it

[@ianbride9866]

I am using an old washing machine drum as my case - lined with ceramic wool and then bricks (which happened to be exactly the right length) tapered-cut (have to be clever to fit the last one by using two off-cuts on a square-cut one) - but looking groovy....!

[@davidwallace1644]

Dude I watch your videos because it’s informative and ridiculously funny. Keep it up

[@PaulsGarage]

Thanks! glad you like the videos

[@Uncle_Bucks_Forge]

Went threw and watched your whole series on this as i would like to build a foundry furnace. Now i know how to do it, or may be not. Who knows but I'll give it a go. Thanks

[@PaulsGarage]

Hi uncle buck! There are lots of ways to make a foundry furnace, It's kinda like a forge turned into a bucket to hold a crucible instead of a chunk of steel. The furnace i'm building won't melt steel, though, only cooler alloys of aluminum and copper. I'm planning on doing a forge next with the leftover parts from this.

[@Uncle_Bucks_Forge]

That is exactly what I want to do. Aluminum and brass. I already have s bunch of stuff for melting and fluxing brass and aluminum.

[@andrewdaniels7076]

Dude just discovered your channel love your humor looks like I have a lot of catching up to do.

[@WarpedLegacy]

The sounds are absolutely necessary. They make everything easier! Plan D makes a much better video than Plan A. Even with all the "janky" that thing looks pretty sweet! Define Your Legacy!

[@frankbmarra1899]

Hey Paul, new viewer, big fan. Your hilarious! (And sometimes delirious). Great job man love your stuff

[@PaulsGarage]

+Frank B Marra thanks! Glad you enjoy

[@brandona4618]

Building a foundry myself. Little but larger tho. Concrete foundation. Solid cinder outer wall. Picked up the refractory bricks today to make the inner structure

[@MaturePatriot]

Wish I had that many vice grips! - I was thinking to myself, "that looks heavy", but at least the wind won't blow it off. Love your videos.

[@PaulsGarage]

Those two on the lid are my only nice vice grips. All the rest are from harbor freight and I wouldn’t trust them to hold up anything glowing hot!

[@Whispersfromtheshadows_]

You are funny! Love your commenting and problem solving. Great videos :D

[@g102684]

“I’ll melt you later” obviously referring to you melting our boredom away with your awesome videos haha love them brotha. You are one cool dude. 🙌🏼✊🏼👌🏼

[@PaulsGarage]

Yeah, we'll go with that :D there's no way a person will fit in this little furnace...

[@garycourt8593]

Good ideas, I would be inclined to make a round cylinder to fit over and then pack it with a high temp grout. A lot of work fitting these angles.

[@waltherbudman144]

guuuuuud stuuuuuuuufffffff!!!!!!! thanks. you are a fun guy.... i love the commentary!:)

[@duuuuuudddeee]

"Should've been slightly less "not quite 45"" that's gonna be my new shop class quote XD

[@PaulsGarage]

+Mr. Slender precise measurement is key to proper fitment ;)

[@luciusirving5926]

Reminds me of my first rocket stove.

[@marcs4738]

Digging the back ground music

[@PaulsGarage]

Thanks! It's a free music track (used with attribution) from Incompetech.com. Lots of cool royalty free music there.

[@JointerMark]

I have been thinking of enclosing my furnace as well. I was thinking of pouring dry sand in between the metal shell and the firebrick to add a bit more insulation and stop any air passing through any gaps in the bricks. I wouldn't worry too much about how the welds look as long as they do the job. Better to have done ugly welds that work than think about perfect welds that never see the light of day.

[@PaulsGarage]

Sand is a good idea. I have some sand here but i was planning on using that for making green sand (it's very fine). Still hammering out the details.

[@JointerMark]

Paul's Garage I am fortunate that where I live there is a lot of sand locally which you can just dig up and bring home. The sand I am using is very fine sand that has accumulated into sand dunes. I dried it out in my oven and will be using it in my greensand as well.

[@TheNocturnalAlchemist]

Ready to see you fire it up and melt some stuff

[@PaulsGarage]

Me too! soon....

[@Kamal_AL-Hinai]

Hey bro. Apparently we share similar interests in KZbin since I see you a lot.

[@TheNocturnalAlchemist]

Kamal AL-Hinai yea I guess so man

[@kev20122012]

fire it up cant wait any tips for starting out welding I got a 125v fluxcore welder

[@eviehart1504]

4:06 I can enjoy a good pun when I see one Great vid!

[@PaulsGarage]

thanks!

[@mazirian9261]

Wow, I remember when you were at 900 subs. :D

[@PaulsGarage]

i remember when i had 45 ;)

[@Kurogane_666]

The type of welding you did that would be considered spot welding or plug Weld and wouldn't it how did you get it to actually weld like that did he drill hole on one side or did you go for it

[@PaulsGarage]

I didnt drill holes. This is pretty thin sheet so the puddle made it all the way through, assuming i had it properly clamped tight

[@ronyerke9250]

If you weld an arrow-shaped (or just triangular) bead on your shell pieces, THAT might help you mark your desired orientation, readable even after it gets rusty. It looks like you have enough scrap steel to make handles, or you could buy some rebar and make handles from that. Nice vid. If you ever remake the shell, perhaps making each piece in 2 or 3 sections will help you avoid hammering on the bricks and mortar. Then just slide the sections on and weld them together. Usung a pin-together design (old door hinges) will make it easier to replace the bricks and mortar if they ever get damaged. But hey, what's the likely hood of THAT happening? Those proper metal bending grunts sound a lot like constipation sounds. :-D

[@PaulsGarage]

+Ron Yerke that’s a good idea! I might try that. A multi piece shell would have worked better too

[@ronyerke9250]

:-)

[@ronyerke9250]

There's vid you might find inspiring: DIY Pallet Wagon by Construct Icon. A downsized wagon like he builds might be useful for your furnace and burner.

[@billywaynemcwilliams9063]

Where did you get that throwback mounting dudes shirt. Awesome.

[@PaulsGarage]

Walmart I think in like 2010?

[@marcus_alf]

The “not quite 45 degree angle” you were talking about it is 40 degrees because in a nonagon, all angles are 140 degrees

[@PaulsGarage]

+Marcus Alferez you’re right, but that requires that I built a proper nonagon. I didn’t, I made a squished one

[@mrgreenswelding2853]

Hell paul your welds arent perfect but they do the job perfectly!

[@PaulsGarage]

Good point! I haven't welded anything yet that fell apart.. it all stays together, it just looks gross.

[@WoodNMetalWorkshop]

Hey when bending that around the top you could have made a light score with the cut off wheel on the grinder, makes it bend easier and where you want it. Looking forward to the next video and FIRE!

[@PaulsGarage]

that's a good idea! I hadn't thought about that.

[@jbwelch89]

lol well u answered my question of the autobody hammer. quick question are you any good with bondo??? im self teaching on welding as well and personally i have a truck i dont wanna burn a giant hole into much as id rather plate the hole correctly.......figured id ask though i know wisc gets more salt than we do here in tenn lol but hey your vids are awsome man keep them up... when ya can family always first...why my street cars being neglected lol was going for autocross or dirt track havent decided yet.......but no rx8 gonna take it . . . . had to if i recall you used to drive one?? and dont get me wrong lol iv had 2 both 2004 and 6 speed manual fun cars but rotary took its toll on me

[@PaulsGarage]

+Johnathan Welch I’ve never tried bondo. Not yet anyway. I still have an rx8, it’s a 2009 R3. You can see it in some of the videos but there’s often a cover on it.

[@jbwelch89]

iv got an 08 at a buddies sadly a auto but that may be in favor if i happen to find an older carbed engine i wanna try to convert it over...well swap lotsa modding though.....but the newer miatas use the same subframe and mounts as yours.......i may look into that maybe? im usually swapping civics and hondas but if not mistaken iv seen miata setups sold on the jdm stuff but i do miss rotory well the 13b but anyway back to the furnace man its awsome!!!! hey you seem to like tinkering any suggestions on a diy belt sander? or ever thought about it?

[@rcpi9336]

Yay First! Cool video Paul

[@franciscoluna9596]

11:31......it looks perfect to me!!!

[@thanielxj11]

At 6:27 new kinds of making. Maybe you should do an Arduino project. It seems tangential at best

[@thanielxj11]

Also I love these videos

[@whoeveriam0iam14222]

your whole channel is "I tried this, but I did something wrong so now I'm using this sub-optimal solution as my solution" makes for good video content. and the jokes about yourself.. that's pretty good too. so I'm glad you had a gaming channel that you stopped doing otherwise I wouldn't have found you but you wouldn't be making these videos if you were still doing videogames

[@PaulsGarage]

+whoeveriam0iam14222 nothing ever goes to plan. It’s the same way I played KSP back in those days.

[@adityapurswani2566]

What is the material of the sheet ?

[@mindofmadness5593]

Nice. Is that Galvanized? My readings says Galv and heat do not play well with ones lungs. Oh and on another note, they found a prviously unknown chamber in one of the Pyramids-Giza IIRC. :)

[@PaulsGarage]

Nope, not galvanized, just mild steel. That may pose a problem later when it starts rusting, but i'll let future me worry about that.

[@shit85head]

Handles, then paint, right?

[@PaulsGarage]

I don't know about paint, I"ll have to see what kinds of exterior temperatures i'm getting when it's all done. I could always 'test' high temperature paint I suppose. That or leave it looking all mad-max.

[@shit85head]

I think high temp paint will be okay.

[@og0rog0r20]

Is the case truly necessary?

[@PaulsGarage]

Yeah the bricks are not very strong and the satanite isn't very strong either. The case holds it all together during expansion of the heat and stuff. You don't have to make a case, lots of people just use a keg.

[@hi_im_redbeard]

Another great vid 👍

[@PaulsGarage]

+Cody Bond thanks!

[@tonyvictor804]

Awesome, but after seeing how much time and how many tools used to make it, I think I'm just going to buy a small metal foundry instead. The tools alone used to make it have to be more expensive than the thing itself. Maybe that assumption is wrong?

[@darktideryezing]

Don't be too hard on yourself for the welding. Welding sheet steel is not an easy task regardless of your equipment. I took a class (at a community college) on it and I could not get the hang of it for the life of me. Oxy-Acetylene welding makes it a little easier because it is painfully slow, but even then, if you have the wrong tip or technique, you're screwed. I think you're doing a great job, the only thing that I spotted that got me concerned was having that metal lip between the two levels of bricks. I would be worried that it would heat up excessively, but I doubt that it'll cause any type of structural concerns though. You've got a really solid design. I wonder if you should use a lift style system for your lid (TAOW did something similar in his electric furnace upgrades, it made it so he didn't have to carry the lid freely, it had some guidance and he didn't have to worry about where to put it down). Nice work in getting in a lot of other skills in your work. You've got a lot of skills in your arsenal and it's pretty awesome to see all the skills you can put to good use!

[@PaulsGarage]

A lifting system would be pretty awesome, i've seen a few but haven't settled on anything. My main issue with welding (i think) is lack of experience and trying to rush through prep. Seems like if I take the extra time to make sure everything is prepped right and clamped right and i concentrate and focus i can make nice looking welds. I dont' have the skills for that to be a quick and easy process like it would be for an experienced pro.

[@treym8561]

Like the build

[@PaulsGarage]

Thanks! it looks much cooler than i expected it to

[@AlbySilly]

2:51 I can just imagine someone building an entire instrument out of this

[@PaulsGarage]

like a musical saw, but worse! :D

[@tonkadriver1833]

You must drink a lot of Mountain Dew to keep up that pace Maybe you could get the local bottling company to sponsor you🤔 Awesome channel!

[@PaulsGarage]

+Tonka DRIVER lol I stopped drinking Mountain Dew a little while ago, switched to coffee. More caffeine per ounce in coffee

[@MrHamof]

Part 4 in this series is private and can't be watched.

[@tirionlanaster2626]

Slice extra brick thin, and reinsulate

[@tirionlanaster2626]

Make housing for tank keep it cool and away from hazardz

[@badsantaclaus4522]

Lmao!. You make my night go to sleep laughing That lid looks heavy Get a sky hook for your lid Can not wait to watch you firer up I bet you can melt steel with that baby how many projects do have going on?. Like me to many to remember lol Thanks for taking the time out of your sleep time to make us laugh.

[@PaulsGarage]

thanks! I'm considering different lid lifting ideas. I was thinking of making some cool handles (maybe cast them with this furnace then rivet them on or something) but given how heavy it is I might reconsider... No idea how many projects I have going on right now, but in KZbin videos only 3 I believe (foundry, gingery lathe, and jeep).

[@esffswfsdfsdf9607]

Your are just awesome!

[@PaulsGarage]

+esffsw fsdfsdf thanks!

[@ffjsb]

Since you like to mix multiple skills, if you keep doing sheet metal with no gloves, you can mix in first aid skills... Seriously, nice video, I want to do this for myself.

[@mjaugugliaro8535]

I respect your craftsmanship. The lid seems very bulky and heavy. Every time need to add more scrap youll need to lift that lid. Dropping pieces from the hole on top isn't efficient. Half of the dropped scrap will melt and pool up around the crucible. I was a dropper through the top hole once so let my mistake be your insight. We need to remove our lids to fill our mold unless you build or find the perfect width pipe long enough to be used as a chute to drop scrap into the crucible with 100% accuracy. *dont mess with 100% graphite crucibles. Look into getting yourself a heavy duty Salamander crucible. 100% graphite deteriorate after 10 uses and they could fall apart and crack way before the 10th time, for the price it just isn't worth it and your best molds are made of iron, again graphite is too delicate. For a nice custom mold invest in some slabs of compressed charcoal if your not into ingots.

[@Gr0nal]

How on earth are you still able to do this much whilst working 50 hour weeks? :O :( I can't do half as much as you and I'm only a university student.

[@tayyebmujtaba2520]

Exactly my thinking! 50 hour work weeks, these massive projects, the huge editing job per vid, AND then Paul time..... I think Paul must be like Doctor Manhattan, making clones of himself.. The working Paul, the Paul we see on video, editing Paul, family Paul etc etc

[@PaulsGarage]

+Not Tayyeb the secret is there is no paul time ;)

[@PaulsGarage]

+PandaManMk2000 it’s complicated but suffice it to say I am totally incapable of sitting still for more than 30 seconds. I must be up, I must be moving, I must be doing something all the time or my brain turns against me.

[@Gr0nal]

Can't tell you how much I relate to that, man. The difference is that my brain turning against me isn't motivation enough to not do nothing :P So I end up not utilising my time and feeling bad about it.

[@dfross87]

You forgot future Paul. He seems to get stuck with a lot of jobs.

[@archangel20031]

Should have made the top and bottom, then connected them in the middle so no need to hammer on the bricks!

[@Hobypyrocom]

damn man, you are fun to watch, your videos are great and the projects are useful and great also, more than a year of making videos, 62 videos so far, and you have only 6100 subscribers? wtf? whats wrong with people nowadays? or other channels (especially those lame ones with useless videos and projects) are spending allot of money for advertisements?

[@PaulsGarage]

+IamIUareU it’s growing fast enough for me, 6100 is already way beyond what I thought would happen

[@Hobypyrocom]

you deserve way more... i was just wandering why good channels like your get way less people than some lame channels... best wishes and keep up the good work...

[@timothymichaud2442]

Dosnt hevknow about hole saws

[@markchrist7785]

Love your vidies man! You are a real inspiration and funny as fuck! Keep up the great work.

[@PaulsGarage]

Thanks!

[@markchrist7785]

Paul's Garage Now go get some sleep before you lose a finger to a pair of rogue tin snip!

[@1pcfred]

If I knew how long things were going to take me to do at the outset I'd never do anything at all.

[@PaulsGarage]

Very, very true!

[@Kamal_AL-Hinai]

What is wrong in bending things in vises?

[@zaph3]

Square with triangular corner inserts would have been much quicker.

[@Joe-dw8sh]

That lid is thicc

[@PaulsGarage]

+joe garrow pointy and sharp? I’m sure it still counts ;)

[@massimoserra4787]

Hi Paul, great to see some progress on the furnace. For now it comes out nicely. We just wrote about a mechanism to lift the lid. I found another very simple way to solve this problem. Take a look on this video kzbin.info/www/bejne/aGacqGdrfbtlnck

[@pumpedgrunt842]

wunderbar

[@PaulsGarage]

+pumpedgrunt danke!

[@TheWeirdSide1]

Mortar Cement K-Bond Wet 3000F Thermal Ceramic Fiber Firebrick Forge Kiln 2 lbs... $26

[@qcdiamond8292]

You really are funny 😂

[@PaulsGarage]

thanks!

[@ultraderek]

I did a spit take on your second to last metal bending grunt.

[@MrGoatflakes]

Part 4 is private Paul ;-:

[@PaulsGarage]

?? It shouldn't be

[@PaulsGarage]

Check in 5 minutes ill fix it

[@PaulsGarage]

kzbin.info/www/bejne/jp_Xe6mMfNpkisU ok there it is. KZbin "vanished" it on me

[@terr1592]

Second! MeTal Please, hah get it.

[@PaulsGarage]

+Terrariabat ha!

[@terr1592]

Ikr I am dying inside.

[@kytrapping5829]

Just measure the bricks and mark it in all the spots and bend bend bend

[@jerichojoe307]

You know, I like DIY and everything; but I've always found it redundant when it comes to products that can be purchased. The amount of time, effort, and material used to make projects like this far exceed the cost of just buying one. People always forget about their time when making DIY projects. I always tell people that when doing DIY take what you make at your regular job per hour and correlate that to the cost of the project. You will find that you wasted more in just time alone producing it than the cost of simply purchasing one already assembled with all of the materials. The only time DIY is feasible is when the time it would take for you to make it combined with the materials needed to make it; are less than the cost of the product, or if there is a specific customization or feature in the use of or a custom part needed for the project that you cannot purchase. I don't see many custom features on this thing that you can't already buy ready-made. And far cheaper in materials and time if again one correlates their time into the cost of the project. There is a ready-made furnace made by devil forge about the size of this one that already comes with a burner and everything for around $1,500. Looking at materials and time you have far exceeded $1,500. It's available on Amazon.

[@subjectofgov]

I knew a man that had too many vice grips.

[@PaulsGarage]

Sounds impossible, never too many

[@scor440]

Who makes them stainless steel thats news to me? Oh i know nobody😂😂

[@ColonelRPG]

My back hurts!

[@thecrudelab3204]

Why would you be drooling

[@PaulsGarage]

+Otago Harbour Fishermen thinking too hard to close my mouth

[@thecrudelab3204]

............ ok................................

[@georgebenson3826]

Making it look ez

[@firebird8600]

My "highly calibrated" eyeball says that looks right.

[@PaulsGarage]

I wish I had calibrated eyeballs!

[@firebird8600]

Paul's Garage they're great for when you forget your measuring stick.

[@robertjackson716]

How sad would you be if you did all this and it didn't even work better than your last one?

[@darktideryezing]

While it may not melt metal any faster (how else could it be worse?), its guaranteed to insulate the heat a lot better just due to the sheer amount of insulating brick, steel, and mortar. It should do really well.

[@PaulsGarage]

I hope it does better! even if it doesn't get hotter it's a lot bigger inside so i'll be able to melt more at once. That's the big issue, the gingery lathe requires some very large castings and i couldn't get a big enough crucible in the little bucket.

[@Chaos8282]

If your wooden bench-top is pristine you aren't using it.

[@PaulsGarage]

Very true

[@dylanjackson7325]

that shell looks matal af

[@Lollipop-yu6bg]

Так себе печь

[@thecrudelab3204]

Hbrigie

[@73superglide62]

Did u say inter sex