Love Casting

foam aluminium skull halloween
from a light foam skull to a 5 kilo aluminium skull
lost foam casting
For God’s Sake not a Damien Hirst diamond skull

first time i melted and made a mold and first cast i ever made
neighbour whas sitting on the roof
waiting for things to go wrong
laughed when my leather motorgloves shrinked 5 sizes and cought fire
by the immense heat off the molten alluminium
laughed when a black smoke arised when i poored in the molten alluminium (foam burnout)
but he whas impressed by the result off this first skull

foam skull i used
5x foam skull + shipping to holland = 100 Euro
http://www.brandsonsale.com/hg-004627.html
another cheaper
http://www.centerstagestar.com/lisirefoskha.html
hee im dutch so cheaper
http://halloweentownfl.com/product/36523975-8ae5-db11-9100-001676ca3a71.aspx
or search for “realistic foam skull” from F.I.T.C.O.
http://images.google.com/images?hl=en&client=mozilla&rls=org.mozilla:en-US:unofficial&resnum=0&q=realistic%20foam%20skull&um=1&ie=UTF-8&sa=N&tab=wi
FITCO (First Imperial Trading Company)
Straight From The Grave
http://www.firstimperial.com/
the foam is burned away when aluminium is poored into the mold
think i used brusselse aarde
no i used bindolzand (rode kneedbare zand / red sticky sand)
from http://www.hazelaar.nl 25kilo = 44 euro

a petrobond sand mold. ?

wasted my motor gloves because off extreme heat
and wasted the chickens water pan

next 2 videos inspired me
http://www.youtube.com/watch?v=3rb8BdMn7B0
http://www.youtube.com/watch?v=yR3ekOrQ1sw

i do not understand the price i payed for the scrap aluminium
on the londen metal exchange LME
the price is 2700 usdollar per 1000 kilo
2.7 dollar per kilo
2.7 U.S. dollars = 1.82679296 Euros
1.82 euro * 22 kilo = 40.18euro and i paid 25 euro
could get sleeping rich if i where a scrap metal dealer

An average aluminium can (without its contents)
weighed 16.55 grams in 1992.
By 2005 the aluminium can weighed about 14.7 grams.
thats 68 / 69 cans in a kilo
aluminium can price is 1.5 usd a kilo or 1500usd per ton

so this skull is aprox 345 cans

Aluminium has a melting point of 660°C
compared with 1540°C for iron

If all the aluminium cans sold in the UK were recycled for cash it would raise more than £30 million for collectors.
Setting up an aluminium can recycling scheme is a great way to raise funds for a charity or good cause without having to ask for donations.

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After the pour. Aluminum, like any heavy metal will recycle 100% (save the stuff still stuck in the crucible). The ingots are perfectly size for the crucible. Once I get my first foam carving done I can just throw these in and re-melt them.

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Finishing a full day of casting by pouring some ingots. This was the third pour of the day. Check out www.budgiemetalworks.ca for details on the furnace. Thanks for watching!

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Here I am casting a part for a Crayford Style Focuser to be used with a 8″ Newtonian telescope I’m building. I’m using a propane furnace, a graphite crucible, and the “mold” is a tin soup can. I need a stock of aluminum about 3″ in dia. Before you say it, I know it is not safe to cast metal with flip-flops and shorts, but it’s the middle of summer in Phoenix here…

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A green sand mold is filled with molten aluminum.

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An aluminum pour, with some problems…

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Precision Airset Sandcasting process for aluminum castings at Armstrong Mold Corp. East Syracuse, NY

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First video of my sons and I firing up our homemade furnace to melt and cast aluminum scraps to make some objects.

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Check out my website: http://www.budgiemetalworks.ca
This is the first casting in my homemade aluminum foundry. Approximately 5 lbs of aluminum was poured here which took about 2 hours to melt. The furnace draws 20A on 220VAC.
It was built from plans bought at http://www.dansworkshop.com/
The element was custom made for me at a pottery kiln shop, the body of the furnace is made from firebricks and commercial refractory. The tools for handling the crucible were made by myself. The amperage controller is sitting on the pink foam on the floor, I’ll be enclosing it properly but wanted to try it out first. The crucible was bought from Canadian Thermix, a really nice company to work with. The final furnace took about 6 months to complete, working on it every couple weekends, and I expect to get a lot of use from it.

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Final test of Jake von Slatt’s waste oil foundry furnace. Aluminum is melted, last year’s turkey fryer oil is burned.

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