YOU CAN MELT SODA CANS INTO SOLID ALUMINIUM
Melt empty soda cans into solid aluminium ingots in a charcoal foundry whose sand-and-plaster lining costs under twenty dollars.
by The King of Random
Workshop
- difficulty
- ●●●○○
- time
- a few hours, plus about an hour for the lining to set
- license
- license not specified
- repo
- repo 0 stars
●●●○○ · a few hours, plus about an hour for the lining to set · license not specified · 0 stars · repo
WHAT YOU’LL NEED
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COMPAREE VERDICT
This is the classic backyard foundry build: a steel bucket lined with a sand-and-plaster refractory, burning charcoal with forced air, which the guide says melts soda cans within seconds. The guide is clear, the lining materials cost under twenty dollars at a hardware store, and the videos show it working. The biggest mistake is underestimating the safety requirements: the guide warns that charcoal foundries exceed 1,000 degrees Celsius, that sparks can ignite fires and that fumes from burning dross can be toxic. If you do not have a fire-resistant outdoor area with ventilation, proper protective gear, and a plan for keeping molten aluminium away from water, do not start. The build itself is simple: you have about 15 minutes to mix and pour the refractory before it hardens, the crucible is the bottom half of an old steel fire extinguisher, and the air supply is a steel pipe joined to PVC. The margin for error once it is lit is small. If you can follow the safety precautions, this is a practical introduction to casting small aluminium parts at home.
IN THE REPO
GOOD TO KNOW
- —Full step-by-step guide on Instructables with photos and measurements.
- —Materials: play sand, plaster of paris, 10 quart steel bucket, 2.5 quart bucket as the core, old steel fire extinguisher for the crucible, 1 inch steel pipe, 1 inch PVC coupling and pipe, charcoal briquettes; the lid uses a 5 quart bucket and two 4 inch U-bolts.
- —Licence: CC BY-NC-SA 4.0 (as stated on Instructables).
- —No CAD files, no repository: this is a tutorial, not a design package.
- —Two YouTube videos: the build and the first melts.
- —Safety warnings in the guide: above 1,000 °C, fire risk from sparks, toxic fumes from burning dross.
Parts to buy
9 itemsFrom our check of the build. Exact quantities and part numbers are in the creator’s BOM.
Can I build this?
Build at your own risk. Projects involve tools, electronics and sometimes mains voltage — follow the creator’s safety notes.
Videos
Melting Cans With The Mini Metal Foundry6:50
Shows the foundry melting soda cans and pouring ingots; about 22.7 million views
More builds like this
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Start here
Navigation into the creator’s own docs — we don’t rewrite the guide, we route you to the source.
- 1.Read the full Instructables guide and watch both videos before buying anything (The safety warning at the start of the guide is not decoration)
- 2.Source a 10 quart steel bucket and an old steel fire extinguisher(The fire extinguisher must be depressurised and the valve removed before cutting)
- 3.Mix equal parts play sand and plaster of paris with water, cast around a 2.5 quart bucket as the core(You have about 15 minutes before it hardens; the guide has exact proportions and photos)
- 4.Cut the air port with a 1-3/8 inch hole saw, sloping down at about 30 degrees, and fit the steel tube(The port sits a few inches up from the bottom so a failed crucible's metal stays inside the foundry)
- 5.First firing outdoors, with protective gear and a fire extinguisher ready(Our suggestion: check the foundry lights and draws air properly before you add any aluminium)
Resources
Documentation, files and community threads for this build — we link straight to the original sources and never rehost the creator’s files.
KNOWN ISSUES
- The refractory mix gives you only about 15 minutes before it hardens: get all the powder wet and lump-free quickly, then let it set for about an hour.
- The air port sits a few inches up from the bottom and slopes downward on purpose, so that if a crucible fails the molten metal stays in the foundry instead of flowing out of the pipe.
- Fumes from burning dross can be toxic: work with good ventilation.
- Keep molten aluminium away from moisture: water trapped under or in molten metal can turn to steam violently.
- Sparks from the foundry can ignite fires: work outdoors in a fire-resistant area, away from anything flammable.
- The foundry and crucible stay hot long after the fire dies down: let everything cool before handling.
How many cans does it take to make a usable ingot?
The video says roughly 38 to 45 cans make about one pound of aluminium.
Can I use this foundry to melt other metals?
The guide is about melting soda cans and casting aluminium. It also suggests the foundry could be used as a blacksmithing forge or a charcoal BBQ, but it does not cover other metals.
How does it get enough air?
Through a blower tube: a 1 inch steel pipe in a downward-sloping port, joined with a PVC coupling to 1 inch PVC pipe. The foundry burns charcoal briquettes with forced air.
Can I use something other than a fire extinguisher for the crucible?
The guide uses the bottom half of an old steel fire extinguisher, depressurised with the valve removed and cut with a hacksaw: a steel cup about 3 inches wide and 5 inches tall. It checks the tank is steel with a magnet. Other containers are not covered.
Community builds
No community builds yet — be the first, we feature the best ones.
Discussion1
FROM THE COMPAREE TEAM
The guide says the foundry melts cans within seconds and the lining costs under twenty dollars, but the real cost is the safety gear and a safe outdoor workspace. What would you cast first if you built one?
The King of Random
The King of Random (TKOR) published this foundry guide on Instructables on 15 January 2015. The melting video 'Melting Cans With The Mini Metal Foundry' (29 December 2014) has about 22.7 million views on the TKOR YouTube channel, and a separate build video shows how the foundry is made.
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DISCLAIMER
- Comparee is not the author of the projects featured here. All rights to each project belong to its creator — every page links to the original source, and we never host creators’ files.
- Information is provided without warranty and may become outdated as projects evolve. Prices are indicative bands only — always check the creator’s parts list for current costs.
- Building and operating any project is at your own responsibility. Protective equipment, safe workshop practice and compliance with local regulations are the builder’s responsibility.
CompareeTEAM2d ago
Practical notes from our verification: the Instructables guide has been live since January 2015, and both videos (the build and the melting demo, about 22.7 million views) are on the TKOR YouTube channel. The surprise is how simple the refractory recipe is: equal parts sand and plaster of paris mixed with water, about 15 minutes of working time and roughly an hour to set. The guide is published under CC BY-NC-SA. Take its safety warning seriously: the project works, but only with protective gear and a fire-resistant, ventilated area.