Tried casting some metal

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I had some fun trying this, never casted anything other than lead.The object was to reproduce a letter from some antique. I suppose the photos will be self explanatory.The original letter is on the left, 99.9% sure it is aluminum. The repro is on the right.

I made a two piece mold using Plaster of Paris.

I melted some aluminum in a ladle using a rosebud flame. The problem was it would not pour into the opening in the mold.It balled up right on top, no go. Tried that three times luckily it didn't ruin the mold. The opening was narrow.

So I had some know to be zinc sheet. That poured right in and came out great. A small amount of flash easily removed with some small files.Finished product is on the right in the first photo.

The letters will be powder coated along with the rest of the antique (don't know what that looks like).Got some learning to do about casting aluminum some other time but it was fun.Ernie F.
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Originally Posted by metalman21

I had some fun trying this, never casted anything other than lead.The object was to reproduce a letter from some antique. I suppose the photos will be self explanatory.The original letter is on the left, 99.9% sure it is aluminum. The repro is on the right....I made a two piece mold using Plaster of Paris....I melted some aluminum in a ladle using a rosebud flame. The problem was it would not pour into the opening in the mold.It balled up right on top, no go. Tried that three times luckily it didn't ruin the mold. The opening was narrow....So I had some know to be zinc sheet. That poured right in and came out great. A small amount of flash easily removed with some small files.Finished product is on the right in the first photo. ..The letters will be powder coated along with the rest of the antique (don't know what that looks like).Got some learning to do about casting aluminum some other time but it was fun.
Reply:In high school, everyone made a sand casting of a desk top aluminum anvil,,I wanted to cast something more "challenging,, the instructor let me make a silver ring using the "Lost Wax" process.The school had a centrifuge to "sling" the molten metal into the mold.When we set off the centrifuge, a HUGE cloud of smoke came out,,, I KNEW it was ruined,,Quite the opposite, the ring was perfect, I still have it!!It was cast out of a "collectors spoon" from Gettysburg,, I doubt that there is much silver in it.It is sitting on a 2 ounce red cup (Jell-O "shot" cup??)The initials were bent out of silver wire, and added after the ring was made.

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Reply:Lindsay publications also sold Dave Gingery’s books.(relatively recent books and not reproductions). One of the books from his “machine shop from scrap “ series is about sand casting aluminum.Simple informative little book. Probably still in print,although Lindsay’sis gone.I built a charcoal foundry  more or less following the plans in the book and made several castings with it.Miller a/c-d/c Thunderbolt XLMillermatic 180 Purox O/ASmith Littletorch O/AHobart Champion Elite