Introduction
This detailed guide explores the step-by-step process of constructing a versatile, high-efficiency foundry and forge utilizing recycled materials and waste oil as the primary fuel source. Designed for DIY enthusiasts and metalworking aficionados, this system can achieve high temperatures suitable for melting aluminum, which melts at approximately 660.3°C. By repurposing old equipment such as 10-gallon propane tanks, air compressor tanks, and automotive blowers, you can create an economical, environmentally friendly, and functional metalworking setup.
Materials Required
To assemble this innovative waste oil-fired foundry and forge, gather the following essential materials:
- Old 10-gallon propane tank: Serves as the main body of the foundry.
- Air compressor tank: Converted into the waste oil burner chamber.
- Automotive blower: Provides the necessary airflow to sustain combustion.
- Three-eighths inch flexible hose: Connects components for fuel delivery.
- Brake line: Used to feed waste oil from a reservoir to the burner.
- 12V marine battery: Powers the blower motor.
- Five-gallon waste oil jug with brass gate valve: Supplies and controls the drip-fed fuel source.
- Old axle and rotating coupling: Facilitate adjustable connection between the burner and the foundry body.
- Insulating materials: Such as plaster of Paris and play sand for internal insulation.
- Welding equipment: For assembly and secure connections.
- Miscellaneous hardware: Including bolts, nuts, and welding rods.
Creating the Air Intake System
Transform a car heater blower into an effective air intake device by housing it inside an old tin can. This assembly is soldered onto a larger soup can and connected via a quarter-inch Schedule 80 pipe, which channels the airflow into the burner chamber. The high-velocity airflow produced by the blower ensures efficient mixing of waste oil vapor and air, facilitating reliable ignition and sustained combustion. Proper sealing and secure mounting are critical to prevent leaks and optimize airflow performance.
Establishing the Drip-Fed Fuel Supply
Implement a controlled waste oil delivery system by utilizing a five-gallon jug equipped with a brass gate valve. Connecting this reservoir to the burner via a flexible hose and brake line allows precise regulation of fuel flow. The setup ensures a steady drip of filtered, clean waste oil into the burner, which is vital for consistent combustion and optimal temperature regulation. Filtering waste oil before use prevents clogging and prolongs the system’s lifespan.
Constructing the Waste Oil Burner
The core of this system is an old air compressor tank fitted with a two-inch cap. To ignite the burner, introduce a heat source and light the waste oil mixture. The blower pipe, inserted at an angle inside the burner, creates a cyclone vortex effect, promoting thorough mixing of atomized waste oil vapor with incoming air. This effective vaporization is crucial for reliable ignition, especially with viscous waste oils. Connecting the burner to the foundry involves welding a three-inch axle and a rotating coupling to the tank, enabling seamless switching between melting and forging modes via a manual lever.
Building the Propane Tank Foundry Structure
Begin by marking and cutting the top of the propane tank to form the main chamber. Inside, apply a cost-effective insulating mixture of plaster of Paris and play sand to achieve approximately 2.25 inches of thermal insulation. Embed the air compressor tank within the mold to shape the interior cavity, allowing molten aluminum to be safely contained during melting. After curing for 24 hours, remove the mold and verify the integrity of the insulating layer.
Next, create an outlet port on the side of the propane tank at a strategic height to prevent backflow of molten metal. Install a three-inch axle through a drilled hole, weld it securely to a rotating coupling, and connect this assembly to the waste oil burner. This configuration allows precise control over waste oil flow and enables rotation between melting and forging positions with a lever mechanism.
Converting the Foundry into a Forge
To adapt the setup for forging purposes, attach a lever system with a latch mechanism on the opposite side of the tank. Construct the lever from a one-inch water pipe, inserting a shaft with a drilled hole to accept a bolt for rotation. Weld vertical rebar to the pipe to form a sturdy latch, enabling manual rotation of the foundry into a horizontal forge position. Support the foundry on a cradle made from two-inch flat bars and one and a half-inch angle iron, providing stability during forging operations.
Ignition involves inserting a small cloth soaked with waste motor oil into the inlet port, then lighting it to start combustion. After establishing a stable flame, connect the 12V marine battery to the blower motor to enhance airflow, sustaining high temperatures necessary for metal shaping. This versatile configuration allows for efficient melting and forging of metals, making it an invaluable addition to any DIY metalworking workshop.