Recycled Aluminum Mask

August 4, 2017 tarannosaurus

Bold Projects → Metal Casting Projects → Recycled Aluminum Mask

After creating the creepy casting of Tom’s hand, which was an enormously good time, we tried to figure out what other random things we could do with our supply of scrap aluminum. We decided to see if we could upgrade from using mud as a molding media to using plaster. And obviously making a plaster cast of someone’s face seemed like a great idea, so we drew straws and Tom’s brother Ben lost. His metal face ended up looking like it had lost an epic battle with acne, which made it that much more creepy and hilarious. I’m not sure what you could ever do with this kind of object, but it provided us a great deal of amusement in the making.

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); we made one the last time we did this project and thought it was a great addition.
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)
plaster
vaseline
straws
plastic hair cover

Step 1: Create your Plaster Mold

Select your victim and use a plastic hair cover to protect their hair, then use vaseline to cover their eyebrows, eyelids, and eyelashes (stuff you don’t want to get stuck in the plaster). Give them breathing straws to make sure they don’t suffocate under the plaster while it’s drying (the plaster will likely block much of their nasal opening so they probably won’t be able to breath well that way). Prepare the plaster according to the instructions, and apply the plaster to your subject’s face. Sit with your subject while the plaster dries in case they need to tap out due to a lack of oxygen. Once sufficiently dry, remove the plaster mold and set aside to finish drying.

Step 2: 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 3: 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 4: 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 5: Prep the Plaster Mold for Pouring

Take the dried mask mold and place it in a soft patch of ground, creating a cavity in the ground so the mold is supported.

Step 6: Pouring your Mask

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 area where the plaster mask is located. Carefully tip the crucible, pouring the molten metal smoothly into the mask, filling it as much as possible.

Step 7: Removing and Cleaning Your Mask

Leave the poured metal in the plaster for several minutes, allowing it to cool. Then, using gloves (it will still be hot!), remove the plaster from the metal, and douse the mask with water to aid in cooling.