I did not see any topic on this type of casting so I thought I would post one. The casting method is called "lost foam casting" , it consists of carving a object out of soft foam then burying it in fine sand then pouring molten aluminium over it. The foam is burned away and the metal takes the shape that the foam was.
Melting aluminum may seem hard to do but it really isn't, a simple air fuelled coal fire will get hot hot enough to melt aluminum.
The crucible can be made of any metal that has a much higher melting point then aluminum, for example stainless steel is a good option. The crucible can mad from a think stainless steel water bottle. a large pair of pliers will work as crucible tongs.
The forge can be made out of a old paint can that is lined with a plaster and sand mixture. Aluminum cans will melt in this kind of forge.
I have tried this method of aluminum casting and it worked out grate for me, I used a paint can forge with stainless steel water bottle crucible. I made a "rambone" style slingshot if anyone was wondering.
I think making nerf parts with this method of casting would be very effective and would produce extremely durable parts. I will be attempting to cast a plunger head that fits a skirt seal, a +bow handle as well as a rainbow handle and pump handle
To showcase how simple and easy this casting proses can be here are some videos of some people with very crude materials and tools successfully using this method
Now a example of someone making something a little more detailed.
Hopefully you find this method of casting as interesting as I did.
Edited by Aeromech, 23 November 2015 - 01:26 AM.