Melting Cans With The Mini Metal Foundry

Smelting Cans Using the Compact Metal Foundry

5 min

πŸ—’οΈ Introduction

Smelting cans using a compact metal foundry is an exciting DIY project that allows you to transform aluminum cans into useful metal objects.

A compact metal foundry is a smaller, more accessible version of the traditional industrial furnace used for metal casting. With the right materials and knowledge, you can create your own mini foundry and melt aluminum cans to cast various items, from ingots for recycling to creative metal art.

In this article, we’ll explore the process of smelting cans using a compact metal foundry, step by step, and discuss the tools and safety precautions required for a successful and safe project.

Creating Your Compact Metal Foundry

To get started with smelting cans, you’ll need to create your compact metal foundry. Here’s a basic guide on how to make one:

  1. Materials Needed: You’ll require a few essential materials, including plaster of Paris, sand, a steel bucket, and a propane torch. You can find detailed instructions and video tutorials on making the mini metal foundry on various online platforms.
  2. Constructing the Foundry: Mix plaster of Paris and sand in a 1:1 ratio. Add water to create a workable slurry. Fill the steel bucket with this mixture, leaving a cavity in the center. This cavity will serve as your crucible.
  3. Allow It to Set: Let the plaster of Paris and sand mixture set and dry for a day or two. This will create a refractory lining inside the steel bucket, which can withstand high temperatures.
  4. Installing a Propane Torch: Once the refractory lining is ready, you can install a propane torch. Position it so that it directs the flame into the crucible area.
  5. Safety Precautions: Ensure you have proper safety equipment, including heat-resistant gloves, safety goggles, and a fire extinguisher, nearby. Melting metal can be dangerous, so always prioritize safety.

Smelting the Cans

Now that you have your compact metal foundry in place, it’s time to start smelting cans:

  1. Gather Aluminum Cans: Collect a sufficient number of aluminum cans. It’s important to note that aluminum has a relatively low melting point, making it an ideal choice for beginners.
  2. Preparing the Cans: Remove any labels, paint, or plastic coatings from the cans. You want to work with clean and uncontaminated aluminum.
  3. Melting Process: Place the prepared cans into the crucible of your foundry. Use the propane torch to heat the cans until they melt. Aluminum typically melts at around 1,220 degrees Fahrenheit (660 degrees Celsius). Be patient and maintain a safe distance while the cans melt.
  4. Casting or Recycling: Once the aluminum has melted, you can either cast it into a mold to create custom metal objects or pour it into an ingot mold for recycling. The possibilities are endless, from crafting custom parts to simply recycling aluminum for future projects.
  5. Cooling and Cleanup: Allow the metal to cool in the mold before removing it. Clean your equipment and store it safely for future use.

Smelting cans using a compact metal foundry is a fascinating and rewarding DIY project that allows you to turn scrap aluminum into something useful. By following the steps and taking safety precautions, you can create your own mini foundry and explore the world of metal casting.


Smelting cans using the compact metal foundry is a great way to get started with metal casting as a DIY enthusiast. It’s a creative and practical way to recycle aluminum and turn it into valuable objects or art pieces. Remember to prioritize safety throughout the process, and you’ll have an enjoyable and fulfilling experience as you explore the world of metalwork.

Frequently Asked Questions (FAQs)

1. Is it safe to smelt aluminum cans at home using a compact metal foundry?

  • Yes, it can be safe if you follow safety precautions and use the right equipment. Always wear protective gear and have a fire extinguisher on hand.

2. What can I make by smelting aluminum cans with a compact metal foundry?

  • You can create custom metal objects, ingots for recycling, or artistic pieces depending on your interests and creativity.

3. How much does it cost to build a compact metal foundry at home?

  • The cost can vary, but you can create a basic setup with materials like plaster of Paris, sand, and a propane torch, which are relatively affordable.

4. What are the advantages of smelting aluminum cans for recycling?

  • Recycling aluminum cans reduces waste and conserves energy compared to producing aluminum from raw materials.

5. Where can I find more detailed instructions for building a compact metal foundry?

  • You can find detailed guides and video tutorials on platforms like YouTube and Pinterest.

Start your own smelting project and explore the possibilities of transforming aluminum cans into valuable metal objects using the compact metal foundry.

πŸ’‘ More Information Is Available About:
Melting Cans With The Mini Metal Foundry

How to recycle scrap metal in the backyard, with a homemade, Mini Metal Foundry.

Common materials in the Mini Metal Foundry

[βœ“] Clay Graphite Crucible:
[βœ“] Steel Pail:
[βœ“] Plaster of Paris:
[βœ“] 2.5 Quart Bucket:
[βœ“] 5 Quart Big Mouth Bucket:
[βœ“] Heat Resistant Gloves:
[βœ“] 1-3/8” Hole Saw:
[βœ“] 3” Hole Saw:
[βœ“] 1” x 12” Steel Pipe:

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WARNING: Charcoal foundries can reach temperatures in excess of 1,000ΒΊC, which is well above the melting point of hobbyists. This project should only be attempted with adequate knowledge and training, proper protective safety gear, and in a fire resistant area with adequate ventilation. The sparks flying from the foundry can ignite fires, and the fumes from burning dross can be toxic. Use caution and common sense. Use of this video content is at your own risk.

Music by: Scott & Brendo (“Skyward” – Instrumental)

Project inspired by:

This foundry is an original design, which comes after months of experimenting, and over 10 different prototypes. The functionality is founded on ideas I collected while searching the internet for foundry designs.


For as long as I can remember, I’ve been intrigued by the idea of melting metal and making things with it. The problem has always been that it was out of reach or required really expensive equipment.

In this project I experimented with 10 different prototypes, to develop a reusable backyard foundry that melts aluminum soda cans easily and safely. I tested different refractory recipes, different containers, different setting for blowing air, and different types of makeshift crucibles.

I tried various ratios of portland cement, sand, perlite, plaster of paris, water, and even kitty litter. For containers, I experimented with clay pots, plastic buckets, no container, cinderblocks, and a galvanized steel pail.

I ended up favoring the galvanized steel pail, and a mix of 50% plaster of paris, and 50% play sand, by volume, which was inspired by a video by NightHawkInLight “How to Make a Soup Can Forge”

Depending on where you get, or find, your materials the cost can range anywhere from $5-$25 per unit. With the materials I used, I was able to make 2 units for under $40 ($20 each). Even on the high end, this is probably one of the cheapest, reliable, backyard foundries that can be made.

I used mine to melt soda cans, and extract the aluminum for future metal casting projects. All the soda cans came from a local recycling depot. I bought back 30 lbs from the depot to avoid having to drink gallons and gallons of soda. πŸ™‚ I stored the ingots in various forms, which you can see in the next video, and tried a cool technique for making a little sword by pouring liquid metal into a bucket of sand. I’m planning to make a project video on how to do that in the near future.

Thanks for watching, and please share!! πŸ™‚
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