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Dual Fuel Gingery Type Furnace

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inthesticks:
I started this build on another forum. I quickly found I was wasting time with a "your new so you don't know anything" attitude. I quikly cut my losses and left.

This is a Dave Gingery style crucible furnace. I chose this style for two reasons. The body lifts out of the way so after skimming the dross, the crucible goes directly from furnace to pouring resulting in less heat loss from handling and greater safety again from less handling.

The furnace body is 16" in diameter by 24" high, cut from a discarded water press. tank. Max. aluminum capacity 30 lbs. in steel crucible. Bronze or iron 24 lbs. in #8 clay graphite crucible, #10 will fit but I don't plan to cast much iron.

I am planning on two types of burners. A Reil type atmospheric burner to melt aluminum and a Lionel Oliver type waste motor oil burner for high temp. metals or when my barrel is full.

Plan Of Action:
1. Build shell and shell attachments.
2. Build carriage and lifting mechanism.
3. Install refactories.
4. Build burners and day use oil tank.
5. Test furnace performance.

Enough talk, on with the build  :clap:. The first photo is the shell cut from water tank, I have a # of projects planned over the next few years so a steel delivery was in order. The 3rd pic is the bottom section with drain hole cut. The last pic. is the burner port cut and ready for burner mount.

I will compleat burner mount and post tomorrow.

Cheers All
CB
 

SwarfnStuff:
So far so good,CB. I shall watch with interest as building a furnace smaller than your project is on my to do list. I was given about 10kg of brass taps a while back plus I also have some aluminium from various sources to play with.
      I shall be starting with a 1litre bucket and finding suitable refractory material within easy distance from home is problematical so that will be a home brew I think. The occasional brass melt dictates choice somewhat but I have found some hi temp mortar sold for pizza oven builds that has a 1000C rating nearby so am starting with that and perlite. Not sure whether to add sand a mortar already contains aggregates, (according to the bag 0-2mm).
      One of my neighbours seems to amass more than a few Al cans that I could also get. There appears to be some discussion on the source of much disinformation regarding the worth or lack thereof in smelting cans. But hey! they're free.

Regards,
John B

DavidA:
John,

FYI, it hakes about 110 coke cans to make up 1 Kilo. And that includes the paint etc.

No idea how much usable metal you get from that.

Dave.

inthesticks:
Hi John B. I have no experiance with peralite but I am told it's ok for aluminum but will break down for the higher temp. metals. I assume your mixing it with the 1000*C refractory if you put a fireclay and sand mix hotface over it, it should give you some protection.

Most peoples objection to pop cans is how thin they are. Heavy oxidation producing lots of dross and resulting melt loss will occur. A very tight crush on the cans will help a bit.

Cheers
CB

shipto:
I used perlite on my elelctric furnace  and I used a mix that I cant actually remember proportions at the moment but it was perlite, cat litter, sand and cement but to make the lid which I wanted a little lighter I added extra perlite while taking a little sand and cat litter away with the result that it was indeed lighter but it seems that it is breaking down quicker than the body of the furnace.

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