Recycled Aluminum Hand

August 4, 2017 tarannosaurus

Bold Projects → Metal Casting Projects → Recycled Aluminum Hand

Similar Projects: Recycled Aluminum Sculpture, Recycled Aluminum Mask

This was our first recycled aluminum project. We initially tried casting some of the evacuated ant hills, but couldn’t find one extensive enough to make anything, so eventually Tom just stuck his hand in mud and we cast that. The result was hilariously creepy. It’s now lying about the garden at Tom’s parents’ house, waiting to terrify visitors. Not sure what else one would do with it, but hey, we had a good time.

Cautionary Note: Unless you have some kind of special facility (you live in a foundry??) we recommend doing this outside – and thus this project is best done in the winter and when it’s wet due to heat and fire hazard (I’m not sure I would recommend doing this in Southern California ever…Tom’s parents live in Florida which would be really hard to set on fire).

What you’ll need:

35 bricks (4″ x 8″ x 1.75″) + one extra brick or brick piece
5 patio pavers (10″ x 10″ x 2″)
2 bags of charcoal
lighter fluid
small crucible (4″ – 5″ in diameter)
optional: lid for crucible to aid in addition of charcoal (it’s kind of annoying keeping the charcoal out of the crucible when you’re pouring it in)
shop vac with extension pipe
scrap aluminum
some way to stir the metal, lift and transfer the crucible
safety equipment: thick gloves, face shields (ignore the fact that we’re wearing shorts in the photos…long pants would really be a better choice)
patch of ground muddy enough to serve as a mold for your hand

Step 1: Build your Furnace

Place four of the patio pavers on the ground to create a base, reserving the last paver for use as a lid. Use the regular bricks to build the walls of your furnace, leaving a gap at the front for the pipe connecting to the shop vac. Place your brick or brick piece inside the furnace and place the crucible on top of the brick. Pack charcoal around crucible, filling the space inside the furnace.

Step 2: Pre-heat the Furnace

Douse the charcoal liberally with lighter fluid, place the shop vac hose in the designated space, and light the charcoal on fire. Once you’re satisfied that it’s caught sufficiently, place the lid on the furnace. Secure the extension pipe to the shop vac tube (because you don’t really want to melt your actual tube, do you?) and set the shop vac to blow air out, then turn it on. This is a critical component to getting your fire to burn hot enough to melt the aluminum. Check the status of the furnace periodically, adding charcoal as necessary.

Step 3: Melt Aluminum

When the crucible has started to glow, add your scrap pieces of aluminum and replace the furnace lid. Check on the status periodically, adding charcoal and stirring the contents of the crucible, and adding additional pieces of aluminum until you have the volume of liquid you want.

Step 4: Create your Hand Mold

When the aluminum is nearly molten, find (or create) a patch of ground fairly close to the furnace that’s soft enough that you can dig your hand into it (but obviously not muddy enough that it won’t hold the shape) and dig your hand into it. Tom opted for the “fingers curled in anguish” look. Always a good choice.

Step 5: Cast your Hand

Once your aluminum is fully melted, scrape as much of the dross as you can off the top, then lift the crucible from the furnace and transfer it to the patch of ground with your hand imprint in it. Carefully tip the crucible, pouring the molten metal until the cavity is completely filled.

Step 6: Removing and Cleaning your Hand

Allow the metal to cool for several minutes, then use a shovel to dig up the section of ground containing your casting. Be careful, since the casting is likely still hot. Wearing gloves, remove some of the larger chunks of ground, then use a hose to wash off the remainder of the dirt, revealing your hand.