Making Electric Aluminum Foundry DIY

I decided to make an electric furnace because it's totally silent, I may use it inside my workshop, I also may control temperature and I don't have to worry about lack of gas or wood coal.
The furnace works perfectly, after an hour of preheating the temperature is ready to melt aluminium. I didn't test it to maximum temperature because 800 degrees of Celsius is sufficient.
An external case is a bit warm but it doesn't pose a problem in using it. I heat workshop in winter so I won't have problem with it :)
I am going to use this furnace mostly to cast aluminium, later I am going to use it on lathe.
Things I used:
REX-C100FK02-V*AN AC 230V
TEMPERATURE SENSOR TYPE K 0 ° C .. 800 ° C
Fotek SSR-25DA SSR-25 DA Solid State Relay 25A
19 Insulating FireBrick J23
Some tools I use in my constructions:
Self made:
Belt grinder 2x48 - • DIY Belt Grinder 2x48"...
Vise - • Super Strong Hydraulic...
Drill press STAND with COOLANT SYSTEM - • Drill press STAND with...
and
Welder IDEAL Tecnomig 200GD
LATHE Cormak 330x770
Band saw Stiler BS 712R
Drill press ZX7016
Chop saw Evolution RAGE 3
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Videos that you may like:
• Making MOTORIZED Plasm... - MOTORIZED Plasma Cutting Track
• Making simple Power Fi... - Simple Power File DIY
• Chain Saw HACK 7 - Dri... - Chain Saw HACK 7 - Drill Attachment
• How to make KEYWAY on ... - KEYWAY on the LATHE
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Social media:
FB: Made in Poland
Insta: made_inpoland
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Music by KZbin library :
Archetype
Arms Dealer
Lottery
Shadows
Still_Standing
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[@NAVYABHAN]

I admire the way you built your project. You make it in such a way that the average person can learn from you!

[@inthemountainswithmeachum3256]

I've been researching ideas and plans for a heat treat oven. The use of electric oven burners gave me the simplest and fastest way to make one.

[@dennisminks8282]

Years ago, I worked for a company building High temp (5,432° C) furnaces. May I suggest instead of troweling the cement, add enough water that it can be "painted on with a brush(skim coat)". We would dip both faces of the joint. This will reduce the amount of cement used and after firing, the gap is almost invisible and less susceptible to cracking or leaking. Once the interior is ready for the electrical elements, skim coat the interior walls and floor. The skim coat should be thin enough to pour. Experiment it, if too thin, add more cement powder. GREAT VIDEO!!

[@kelvin869]

You are clearly a man that takes pride in his workmanship and ability. Nice job.

[@CMDRRZulu]

this dangles around perfect cure and posion for my ocd, its so satisfying and painful to watch at the same time

[@jurikizikov8525]

Nice job! You could also drill tiny holes in the edges of front plate for controller. This would make easier the way to cut out.

[@rusticagenerica]

The moment you cut a square hole with that round grinder is EPIC.

[@paulgreenlee190]

Well there are many great things built in Poland, Your furnace is another to add to the list. Enjoyed your video, many thanks

[@dieterbuchner1214]

Made in Poland is great. I always learn something. Thank you for the video. Regards from Germany.

[@haugstule]

11:30 that control box is meant to withstand - atom bombs, emp's fall from 10 kilometers hight, being submerged 10 km under the surface of the sea. impressive.

[@iteerrex8166]

lol Exactly what I was thinking. I guess easier and faster then messing with sheet metal.

[@garybaris139]

...and a direct hit from a tank projectile...

[@garybaris139]

@@gary851 lol

[@johnnywalker2947]

What are you talking about.They baby is going to fail quite quickly. 12:42 do you see those ventilation slots in the controller. Did you see any made in that steel box? Did you notice he but that 25amp max relay in that unventilated box with the controller?

[@garybaris139]

@@johnnywalker2947 , did you notice that the SSR has the entire box as a heat sink? Have you ever seen one of those controllers in use? I've not only seen many in use in much more confined spaces but have also installed quite a few in confined and un-ventilated boxes through the years and I've yet to see one fail because of it. Besides that, we were talking about the box, not the contents and the reference made to the box was in reference to the mechanical strength.

[@chadherrick3433]

Man I love seeing people build stuff! I have a similar lathe and I dream of smelting all my beer cans into billets to make stuff! Thanks for posting this!

[@lchurch0174]

Every time I think this guy is done, he adds another feature.

[@mikemillken2874]

Even put a gauge on his hydra-vise?? I must of missed that video! Cool

[@BludDK]

Восхитительное видео! Грамотно и со вкусом! Благодарю за работу и вдохновение!

[@dawidoszkiewicz5607]

Bardzo dawno nie oglądałem Twoich filmów. Pamiętam jednak te sprzed lat. Muszę przyznać że widać ogromny postęp w czasie! Doceniam szczególnie zwracanie uwagi na drobne detale. Super! Im dalej tym lepiej!

[@conkor97]

This foundry is beautiful, the care put into making it is amazing.

[@flyifri]

I really enjoyed watching in fine detail.! Well done with a big thumbs up, and a thank you for sharing on KZbin.!

[@Sctronic209]

You amaze me every time I watch one of your videos.👍👍👍👍👍

[@ProjektHeld]

I like that you use simple things and often things that other people throw away! Kind of recycling

[@improvisando5623]

Is called upcycling :)

[@villiersman951]

one mans trash is another mans treasure

[@tomsmith3045]

This is a great design. Love your bandsaw setup! I don't think I've seen a nicer vice/pivot setup on a bandsaw before. Also excellent techniques on working with those fire bricks. I'm taking notes on the various ways you were cutting and shaping them.

[@fishtinandcopper179]

A really nice build, a great combination of precision and freehand skills. Thanks for sharing.

[@miikapekk5155]

Your oven is quality workmanship! Before my father died my parents used to run an engineering business , They did non ferrous casting. Aluminium, zinc , bronze\brass and the furnaces looked almost the same, circular with insulation brick walls but on a much larger scale. They didn't use electric just coke(coal), a giant blower fan and a crucible made of silicone, Graphite or steel for Zinc. It was fucking noisy and dirty. So electric is much safer because coal produces loads of unhealthy fumes & carbon monoxide.

[@xv3672]

@Ognjen Radojevic Tradition =/= better, this is why we need newer technology.

[@PugWinter]

Depending on your state, it can be likely you get your electricity from coal being burned.

[@grzegorzglina5149]

Niesamowite, jakość wykonania, dbałość o szczegóły i sam pomysł MEGA. 👍👏👍👏👏

[@wiktornowicki1706]

Dokładnie tak

[@qwekwe]

dbałość o szczegóły? to czemu na niektórych bloczkach "23" do gory nogami? 🤔 nie moge na to patrzeć 🥺😰

[@renosi5975]

Performing work to fit the parts of the furnace without a respirator surprised me. And so the execution is very high quality and well thought out.

[@jaxxonbalboa3243]

Dude, you make me want to go and weld something!............nice job.

[@nicoepsilon0]

that was beautiful to watch, you are very skilled and hardworking

[@americanrebel413]

I scrapped out a stove like this one and head this in mind to make, Then I run across this video, AWESOME! Now I know how! Thank you for sharing this! I subscribed!

[@captainz9]

Please wear appropriate protective gear when cutting high silica high-risk fire bricks. An N95 face mask and goggles at a minimum. en.m.wikipedia.org/wiki/Silicosis

[@michaelray5247]

I'm impressed! Very cool! Great workmanship. Makes me want to go scrapping for aluminum. Definitely a project I'd like to build. Only if I had the time.

[@taunteratwill1787]

Yeah the 'time'. . . . . . right. :-)

[@iamachinesepetwholies5476]

Not only fire bricks are expensive, to think you'd have to cut so much of it inorder to make this is really a mouth opener

[@keithspencersr.6806]

Very smart, great idea, enjoyed your video of the project

[@dapperdave2090]

NICE!!! well planned project... excellent craftsmanship and assembly using quality materials...

[@Noteven0]

You sir are truly a Master Craftsman! Outstanding work!

[@beeman1885]

I just stumbled onto this channel. What a gem - so many ideas and skills demonstrated without one spoken word. Very impressive. Quickly subscribed.

[@blurryeyestf2]

Idk why its in my suggested videos and why did I watched it but have my subscribe and like that was impressive

[@Richard-wk9le]

Outstanding work I salute you keep it coming

[@jothain]

Thank you for sharing your idea. This goes to the few selected videos that are stored, in addition to liked 👍👍

[@silverismoney]

Nice idea using the hob elements. They look like the perfect shape/size

[@skwhite4285]

Hi from Ukraine, and thanks for the very good idea! It's amazing! Temperature control, powered by electricity, and so small and portable. I will make this for my mini home workshop. Thanks again and good luck in your workshop.

[@dieparedes5642]

V

[@bumstudios8817]

Wow... the best fabrication skills

[@gilthomas8020]

Waouh! I was watching your video with love! You work like a Cook prepare his cake! You are really an incredible perfectionist worker! Thanks for the good moment

[@undernetjack]

Really nice production. I feel like I could build one from watching the video. Great Job!

[@jeffalessi]

Be very careful when adding beverage cans to your furnace any remaining liquid will turn to steam and cause a molten metal eruption.

[@derekcooley9345]

Jeff Alessi The easiest way to avoid that is a preheat. I've worked with different foundries, and you can throw a wet charge in, if given enough time to evaporate liquids. That's why I think a gravity fed setup works the best. Preheat some material, melt, then stick larger pieces in to act as a stand, and continue. As the material liquefies, the next batch is preheated. Huge metal pops are no fun. The foundry I work at now had a leak in the roof, and a SOW mould had sitting water. One of the workers saw a bubble forming, so he walked away. About 5 seconds later, it sounded like a shotgun went off, and molten metal hit the ceiling (which was about 80 feet high.) Luckily, no one was hurt, and the leak was sealed by the aluminum that cooled.

[@jeffalessi]

@@derekcooley9345 We do production casting daily and completely agree with preheating however we both know what can happen when liquids hit molten metal.

[@derekcooley9345]

Jeff Alessi As long as it's only on the surface, it's all good haha.

[@cjsmith1713]

That’s why you make sure the cans are washed out and there a couple weeks old before you melt down

[@lazyh-online4839]

@Bobby Fisher I've seen someone get half their face melted off because they wanted to prove exactly what you just said, added just about a teaspoon of water to a steel mold to prove a point and poured in the melted aluminum, half of it went onto the floor, about a quarter of it stayed in the mold, and another quarter went to work melting off his ear, cheek, left eye, and a big chunk of his shoulder and burned off most of his hair on that side of his head. But hey, at least he's not a pussy, right? The thing that sucks was he was left handed and left eye dominant, so it got his good side real bad.

[@MCsCreations]

Fantastic work, dude. Really well done!!! 😃

[@darthslackus499]

Why do I find this therapeutic watching this? I'm never going to have the skill nor the tools to build one.

[@maxjohnson1758]

Ha! Every time I see someone break out a welder I think to myself, "Oh, no."

[@an_what]

Genghis Kong because when you watch a master craftsmen/ craftwoman just being allowed to watch them work is payment enough for your time

[@an_what]

Max Johnson that makes absolutely no fucking sense! To the point to where that’s even a non-statement

[@antr7493]

because it's inventive and great craftsmanship

[@johnbarbour3788]

@@an_what It made sense to me...

[@PaddyNinja]

Oglądanie rzemieślnika przy pracy to prawdziwa przyjemność. Dziękuję Ci.

[@giovannibortot1038]

such an expert worker! a pleasure watchig this

[@coryhalvorson8874]

You are a genius, finally the youtube algorithm works.

[@thubprint]

The mushroom stopper for the top is my favorite part 😄

[@WireWeHere]

Thermocouple wires are dissimilar metals joined at the hot junction to measure the temperature by reading the very small voltage differences that are predictably related to the temperature. Cold junctions happen every time another metal is added and change the calculated value. The cold junction at the PID controller is unavoidable but it's best practice to avoid adding any more. What I'm getting to is to cut off the crimp on fittings supplied with the thermocouple and put the TC wires directly under the screw. I just thought I'd share that little bit of information. Cool project. Peace.

[@vovvov2065]

Зрелище чужого труда завораживает...

[@chinozablah]

amazing work, you have great skills. congrats

[@Maxiscorrupt]

Amazing work almost over-engineered but my god you did not cut any corners. I am so Impressed...

[@danielcoetzee5793]

Aaaaaaaaaah, It's a thing of beauty...! Great job..! Makes me jealous...!

[@Random_stuffs]

that was incredibly satisfying to watch!

[@michaelwilliams6431]

Never thought I'd be happy my oven is broke. This is definitely getting done in the next month.

[@handmaderestor]

*Looks really good, I’ll have to use that trick with heating up the metal and putting it in oil*

[@user-cc6uj6fj5i]

Не устаю удивляться этому мужику! Прям гений какой то!)))

[@mtbshadow]

Fajnie się rozwinął Twój kanał odkąd bylem tu pierwszy raz, gratuluję i subskrybuję :)

[@konstantinsayko7435]

Рукастый ты парень! Благодарность за серию. Однозначно - подписка! Привет из Красноярска !!!

[@Bowtie41]

Pretty Goddam nifty,except now I know where my tent poles went!Love the ladle and the cradle you made for it to set in the furnace,smart!

[@peregrine1970]

That was a very impressive build. Excellent job!

[@jaromirdziewic]

Ale czad! Grande szacun- jestem oczarowany, ogląda się tak dobrze jak najlepsze filmy, wciąga na maxa. Efekt końcowy wymiata. Zmotywowałeś mnie do roboty. Idę do warsztatu!

[@hellboyyyironman1325]

Awesome work bro👍we look forward to more videos...

[@Tony-nl6pf]

What a quality foundry. Well done!!

[@spehropefhany]

Nice work! Recommended thermocouple insertion depth is 10x diameter, so 50mm for an 5mm diameter high-temperature probe (or 80mm for an 8mm one), otherwise it will read low (temperature will be controlled higher than setpoint).

[@RuleOfRage]

Warning: The Dust those bricks give off is really nasty, wear PPE (IE respirators or atleast a n95)

[@109Rage]

Yeah, just looking at the video of all that dust gave me lung cancer.

[@DamithaNadeeshaWanniarachchi]

What about Aluminium fumes?

[@AmongUs-vj1ew]

@@DamithaNadeeshaWanniarachchi don’t worry about it to much but wear one anyway because stuff in aluminum from not being pure can be semi toxic

[@michaeladam626]

5 minutes

[@kinbolluck476]

U can replace firebrick with bread

[@ralphmourik]

Awesome build, my big metal melting furnace is still charcoal powered, I got a small electric one, I want to bluid a big electric one like yours, you got yourself a new subscriber!!!

[@mrstreith]

Ништяк, браток! Получил огромное удовольствие от процесса постройки, руки у тебя золотые!

[@AskRemy]

Wow, incredible workmanship

[@WorkshopFromScratch]

Świetny pomysł, oraz wykonanie jak zawsze na wysokim poziomie 😀 Pozdrawiam 😀

[@jasonwills1116]

Brilliantjob, youmade, itlooksoeasy.welldone.

[@prakharmishra3000]

Isyour spacekeybroken?

[@Firenamer2]

@@prakharmishra3000Whatsa, spacekey?

[@prakharmishra3000]

@@Firenamer2 itsa bigbar inspace calledspacebar

[@0XAN]

man i'm speechless: you are the best!

[@davemcintoshyt277]

BEAUTIFUL WORK.RESPECT from the UK!

[@haithamkittana5411]

Great job. I like watching people manufacturing things

[@MateuszDoniec]

Jest i piecyk :) Polak potrafi Pozdrowiam 😉

[@archieb9461]

very nice job. In Botswana I had a lot of trouble buying aluminium round stock and bronze or brass round stock for my lathe so I made something similar using propane. It was not as smart as yours though!!Well done! I struggles to find material for crucibles but used thick steel pipe which would last for about 5 or 6 melts. Ceramic crucibles were not obtainable but a friend of mine found some ceramic cookware which he said worked fine

[@danieldaniel8314]

Super robota! Niesamowite pomysły u wykonanie. Z moim warsztatem nie byłoby tak szybko stworzyć coś takiego. 💪

[@user-zi3sh9nc1y]

Великолепно! Автору респект!

[@IonutJaR]

Hi, I have some questions and some suggestions to. as I've build few Electric Ovens used for Heat treatment of steel. So suggestion first, J23 bricks wear very easy I've protected the inside of my ovens (bottom of the oven) with Stainless steel sheet, I think you should put some stainless steel where your crucible is resting and also put some protection above the heating element(shortcuts due some objects dropped in are a hazard ). Second suggestion is to use ceramic connectors between resistance and power source(in video looks like ordinary plastic connectors there) .Also the structure resistance rods you have used for the lid should be stainless steel(I've learned this by hard way when I had to replace a top of the oven ) . My question is what is the power of the heating element for your furnace, and what type of the cement have you used between bricks. Nice video by the way and I'm a subscriber and I love your work. Keep it on!!

[@aaronmcshane6198]

My man, you have got some awesome skills. Love all the projects you do.

[@pdj26]

Great video thank you for sharing I love the way your videos are made great process, seems like a very nice little smelting Forge you got there, great job

[@damnoldguy]

I may have said this here before but it bears repeating.....you are going to be worth your weight in gold during the apocalypse

[@MaturePatriot]

I plan to avoid the apocalypse by being in the rapture!

[@ArnaudMEURET]

Gold won’t be worth anything during the apocalypse.

[@damnoldguy]

@@ArnaudMEURET not about the gold, it's about the skills. Please try to keep up. If you paid attention at all you would know he can make just about anything.

[@MaturePatriot]

@@ArnaudMEURET Yes, food will be more costly than gold. I have invested in a lot of brass and lead.

[@lazyh-online4839]

Unless the apocalypse comes from alumina dust inhalation, in which case he'll be one of the first to go.

[@kevinsmith8516]

Very, very impressive You've used some sophisticated machine shop tools but it obvious that basic hand tools, for example a cheap grinder and stick welder, will do the same job albeit slower. Your channel is (arguably) one of the top 10 "make-it' channels on KZbin because it features very useful projects, uses re-purposed parts or sheet metal to reduce costs, has clear instructions and is well filmed Many thanks for your terrific content!

[@alm0nd.359]

The Human is really creative. Wonderful

[@kenbar4761]

Really enjoyed your video, thank you. You are very skilled.

[@DomingesWeld]

Zajebista robota 😁 wow zresztą jak każdy twój projekt szacunek pozdrawiam

[@gasperajdnik5627]

You are a wery smart guy 😎keep Up The god work

[@rupert5390]

Absolutely brilliant - why are poles so good at a variety of engineering and practical things ? Thanks.

[@kylejolda2170]

I'm polish and my grand father was an engineering professor. Lol

[@2to253]

Because we need to be able to survive anything. And so we will. ;)

[@volpeta]

Nice professional work . You are an talented guy! 👍

[@juanvalverde464]

It´s very cool, you´re a genius!

[@SantehnicLive]

Как всегда ЛАЙКОС от САНТЕХНИКА 👍👍👍👍👍👍👍

[@billyhagerman4759]

You are an artist! Very well done.

[@stakittystakstack5493]

This is the best thing I’ve seen the entire time I’ve known KZbin. Awesome!

[@-joe90]

Master 👍🏻

[@arssend]

Мастер! Смотришь видео, и хочется повторить!

[@megamannyeah]

much respect!

[@overspeed3042]

You my friend are a genius

[@user-kr6zu3zs9v]

Отличное исполнение и нужная вещь. Респект!

[@user-kv3ez2hd1n]

норм печка.мне-бы такую.но заморачиваться не охота.мужик молодец.респект

[@chiboreache]

если хуйней не страдать и не ебаться снимать фаски, а просто сложить куб и обварить полосой блять хотя бы немного тоньше танковой брони - то хуйня, делов на вечер, два, под пивчанский

[@BrianFedirko]

You are an Artist. Beautiful.

[@huggi3s77]

it's avesome! man, you have golden hands!