This is something Aarron has been working on for a while now. He still doesn’t have it down perfect but he is getting there. It’s a fairly long and drawn out process that takes about 4 hours from start to finish. Sadly most of it has to be done in order because he has found out that if he make the sand cast early, it usually falls in before the aluminum is ready to pour.
The first thing he does is get a good hot fire going so that he can melt the aluminum down to liquid again. After he gets it close to liquid, he starts getting the mold ready. He made a couple wood frames to hold the sand for the mold.
The sand that he uses has been mixed with bentonite clay to make it more sticky so it will hold the shape better.
Once he has the mold ready, he said that he uses a powder or something to make sure the newly made piece will come out easy. Once the aluminum is ready he will pour it into the mold and let it cool. So far, he hasn’t made a perfect piece yet, but he is getting close. He keeps tweaking how he does this until finally he will get a perfect piece. The best part so far has been the picture below.
As you can see, it’s not quite right yet, but he is getting there. If anyone has any suggestions on what he could do to get closer it would be greatly appreciated. I know that he is getting frustrated with the results of this sometimes.
Have a great day!