Building a Iron/Steel Foundry: Primitive or Modern?

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SUMMARY

This discussion centers on building a foundry for melting iron and steel, with a focus on constructing a bending brake for 5mm thick mild steel plate. The participant is considering a tilting furnace using an oxy-acetylene burner or a coke-burning cupola for melting. Recommendations include consulting Steve Chastain's books on Oil Fired Tilting Furnaces and Iron Melting Cupola Furnaces for detailed guidance. The conversation emphasizes the practicality of DIY foundry projects and the importance of designing efficient systems to avoid wasting resources.

PREREQUISITES
  • Understanding of foundry processes and metal melting techniques
  • Familiarity with oxy-acetylene welding and cutting
  • Knowledge of furnace design, specifically tilting furnaces and cupolas
  • Basic principles of metalworking and fabrication
NEXT STEPS
  • Research the construction and operation of tilting furnaces
  • Explore the design and functionality of coke-burning cupolas
  • Study the contents of Steve Chastain's books on foundry techniques
  • Investigate alternative materials for casting, such as brass and aluminum
USEFUL FOR

This discussion is beneficial for DIY metalworkers, hobbyists interested in foundry work, and anyone looking to build custom metal fabrication tools like bending brakes.

Evil Knievel
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Hi everyone. I would like to build my own foundry, if possible to melt iron. From all the research that I have done, I can see that almost everyone opts to melt aluminum, even when it comes to building a metal lathe. The reason why I would like to melt iron/steel is that I am also wanting to build a bending brake capable of bending 5mm thick mild steel plate and I need to cast the jaws. Brass is expensive but maybe it is cheaper than building an iron foundry. What metal would you suggest?

Currently I am considering building a tilting furnace with a oxy-acetylene burner. :devil: Am I being stupid? The other option is a coke-burning cuppola. The reason why I am considering a tilting furnace is because I don't think one should waste expensive gas to heat a crucible. To quote a fellow DIY'er: "If primitive man could do it in primitive times then primitive man can d it in modern times" Any ideas?
 
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Have a read of Steve Chastain's books, - Oil Fired Tilting Furnace and Iron Melting Cupola Furnaces,

ISBN 0-9702203-0-8 Coupla
ISBN 0-9702203-1-6 Tilting

I'm sure they'll tell you more than anyone here can! Although building your bending machine seems like enough of a project, you definitely don't just want to outsource your forged parts?!
 
Cheers! Actually I have reworked the design and it now takes fabricated parts. Took a lot of thinking! Yeah, I guess the books are the way to go. Keep well.
 

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