General welding questions that dont fit in TIG, MIG, Stick, or Certification etc.
User avatar
  • Posts:
  • Joined:
    Fri Oct 02, 2015 8:37 am
  • Location:
    Sydney, Australia

After a bit of research it seems a blanket and coating i.e. kaowool and itc-100 seem to be the most efficient fuel wise. Not to mention easier to make and a whole lot light than a 2" thick layer of refractory cement.
Nowadays people know the price of everything and the value of nothing... Oscar Wilde
Poland308
  • Posts:
  • Joined:
    Thu Sep 10, 2015 8:45 pm
  • Location:
    Iowa

Look for a boiler wholesaler that deals in industrial boilers. You can get it in any form you want. Powdered can be mixed like drywall mud. Thin or thick as you like you can pour it in or make it like clay and mold it. They sell blankets from 3/4inch thick and up. 2 inch is the thickest I've used. Or you can get the solid bricks that you cut/ rasp into shape. If you need to PM me I can get you a phone number of a company I deal with a lot out of DesMoines Iowa.
I have more questions than answers

Josh
exnailpounder
  • Posts:
  • Joined:
    Thu Dec 25, 2014 9:25 am
  • Location:
    near Chicago

Poland308 wrote:Look for a boiler wholesaler that deals in industrial boilers. You can get it in any form you want. Powdered can be mixed like drywall mud. Thin or thick as you like you can pour it in or make it like clay and mold it. They sell blankets from 3/4inch thick and up. 2 inch is the thickest I've used. Or you can get the solid bricks that you cut/ rasp into shape. If you need to PM me I can get you a phone number of a company I deal with a lot out of DesMoines Iowa.
My old boss is a Redline dealer so he can get me refractory at cost so I have that end covered but the Kaowool blanket is going to be hard to get only because you have to buy a certain quantity and it isn't cheap. Do you know if they sell small quantities?
Ifyoucantellmewhatthissaysiwillbuyyouabeer.
Poland308
  • Posts:
  • Joined:
    Thu Sep 10, 2015 8:45 pm
  • Location:
    Iowa

I think they will cut off of a big roll a foot at a time. I thing the roll is 48inches wide.
I have more questions than answers

Josh
exnailpounder
  • Posts:
  • Joined:
    Thu Dec 25, 2014 9:25 am
  • Location:
    near Chicago

Poland308 wrote:I think they will cut off of a big roll a foot at a time. I thing the roll is 48inches wide.
I have a call in to a friend at the refinery near me. He says he can get me some....have to wait and see but I appreciate all the help. Just got a price on refractory...approximately $160 for 2800 degree. $140 for 2400. My customer is so excited he's been texting me all morning... 8-)
Ifyoucantellmewhatthissaysiwillbuyyouabeer.
User avatar
  • Posts:
  • Joined:
    Fri Oct 02, 2015 8:37 am
  • Location:
    Sydney, Australia

I was looking a back in November or so for kegs for this. I found someone selling them in Sydney on ebay for 80 each. Seemed reasonable, I don't know what they are worth but I supposed to a homebrewer thats a pretty good price?

Anyway, found a guy today on Gumtree. Has about 10. Wants $20 each for them. I might buy 5 or even the whole lot. Make some BBQ's out of them and sell them. Gotta be some other good uses for them. Not sure why they are for sale, when do they cease being suitable for beer? Photo looks like the back dock of a club or pub.

Image
Nowadays people know the price of everything and the value of nothing... Oscar Wilde
User avatar
  • Posts:
  • Joined:
    Mon Nov 04, 2013 7:51 am
  • Location:
    The Netherlands

Very complete series on a home-built furnace from myfordboy on Youtube:

https://www.youtube.com/watch?v=Zbnroan ... ZsP2z0pfeZ

Bye, Arno.
exnailpounder
  • Posts:
  • Joined:
    Thu Dec 25, 2014 9:25 am
  • Location:
    near Chicago

Rupes wrote:I was looking a back in November or so for kegs for this. I found someone selling them in Sydney on ebay for 80 each. Seemed reasonable, I don't know what they are worth but I supposed to a homebrewer thats a pretty good price?

Anyway, found a guy today on Gumtree. Has about 10. Wants $20 each for them. I might buy 5 or even the whole lot. Make some BBQ's out of them and sell them. Gotta be some other good uses for them. Not sure why they are for sale, when do they cease being suitable for beer? Photo looks like the back dock of a club or pub.

Image
I do quite a bit of keg modding for homebrewers. Some of them will only use brand new kegs while others will use aged ones. If you can find kegs cheap...grab them. You can always turn around and resell them for some extra beer money and they will never go down in value so I always have a few laying around. The guy I am building this furnace for was thrilled to know I had a keg for his project and the means to get the job done. Homebrewers, especially new ones, will spend money freely to get up to speed with their colleagues and not look like a noob. I don't know when/why they retire kegs..maybe when they get dented up really bad and the metals strength might be comprimised. Grab those kegs...thats a deal!
Ifyoucantellmewhatthissaysiwillbuyyouabeer.
User avatar
  • Posts:
  • Joined:
    Thu Jan 06, 2011 11:40 pm
  • Location:
    Near New Orleans

I'd run the serial #s past any listed/stamped owner/distributor on the kegs, to be sure I wasn't buying a "hot property", so to speak. That price is remarkable, to say the least. I think I paid a bigger deposit than that on the last keg of beer I bought for a party 30 years ago.

...always wise to cover one's behind...
Worst case, you might get a finder's fee if you do the legwork to confirm whether or not the sale is legal.

Steve S
Tom Osselton
  • Posts:
  • Joined:
    Sat Aug 15, 2015 12:33 am
  • Location:
    Calgary Alberta

I've seen them on Kijiji in Calgary for $20 / 25 bucks, I've been thinking about using one on its side for a forge setup.
exnailpounder
  • Posts:
  • Joined:
    Thu Dec 25, 2014 9:25 am
  • Location:
    near Chicago

20170131_154814.jpg
20170131_154814.jpg (60.49 KiB) Viewed 1606 times
Got the top prepped and poured yesterday. I put several screws through the top for anchors for the refractory to grab onto. Cut most of the top skirt off the keg but left the handles , trying to reduce weight a little. I am going to add pics as I build this as kind of a tutorial for anyone that might be interested. Going to pour the floor and start on the burner today. My customer, who builds high-end custom pool tables, told me he wants to cast pocket corners with it. He is working on the prototype. This is going to be an interesting project. Sorry you had to break your neck to see the pic.
Ifyoucantellmewhatthissaysiwillbuyyouabeer.
exnailpounder
  • Posts:
  • Joined:
    Thu Dec 25, 2014 9:25 am
  • Location:
    near Chicago

20170201_134128.jpg
20170201_134128.jpg (52.01 KiB) Viewed 1599 times
My prototype burner. Nozzle shroud comes off to change nozzles. Used a.035 mig tip for a spray nozzle. Got an air reg going on the air fitting. Gonna play around with it this weekend. I love doing stuff like this.
Ifyoucantellmewhatthissaysiwillbuyyouabeer.
Artie F. Emm
  • Posts:
  • Joined:
    Thu Jul 24, 2014 7:53 am

What fuel are you using? I have been looking into this for a project, and have been considering a waste oil burner. The web has a wide range of ideas on the topic.

If you don't mind a newbie question: how does your burner work? Do you mind showing an exploded view?
Dave
aka "RTFM"
exnailpounder
  • Posts:
  • Joined:
    Thu Dec 25, 2014 9:25 am
  • Location:
    near Chicago

20170201_151027.jpg
20170201_151027.jpg (53.31 KiB) Viewed 1592 times
Here it is running. The addition of air makes a giant difference. I may go down to a.030 tip and see what happens. I will show a closeup of how it's built. Pretty simple.
Ifyoucantellmewhatthissaysiwillbuyyouabeer.
Tom Osselton
  • Posts:
  • Joined:
    Sat Aug 15, 2015 12:33 am
  • Location:
    Calgary Alberta

Looks good! If you want to control the gas flow get a regulator or use the ball valve but I wouldn't change it until seeing how it runs in the furnace.
Jim FLinchbaugh
  • Posts:
  • Joined:
    Thu Sep 01, 2016 11:56 pm
  • Location:
    Kalispell Montana

I bought my TIG welder t go along with my aluminum casting hobby :lol:
My furnace is built from a 30 pound propane tank
Image
Image

You will find making your patterns to cast the parts to be fun, at least I do.
Follow the myfordboy link posted previous, he has a ton of good info, and has no blabbering while making his videos.
It makes them much more enjoyable to watch

Here's another forum you may find helpful- all about casting stuff!
http://www.alloyavenue.com/vb/forum.php
Jim FLinchbaugh
  • Posts:
  • Joined:
    Thu Sep 01, 2016 11:56 pm
  • Location:
    Kalispell Montana

BTW< you re headed down a long twisty involved highway.
You thought welding stuff took you off on rabbit trails, you start
casting aluminum and pretty soon you are trying to turn everything into a casting project :mrgreen:
It is highly rewarding to be able to cast your own parts and pieces.

For casting alloy, forget anything extruded and pop/beer cans.
You want old pistons, cylinder heads, engine parts in general and anything
that was previously cast aluminum.
Wheels are about the highest quality aluminum you can get for the home hobbyist.

CHECK EVERY UNKNOWN PIECE before melting scrap to make sure it isnt magnesium!
vinegar is your freind
exnailpounder
  • Posts:
  • Joined:
    Thu Dec 25, 2014 9:25 am
  • Location:
    near Chicago

Jim FLinchbaugh wrote:BTW< you re headed down a long twisty involved highway.
You thought welding stuff took you off on rabbit trails, you start
casting aluminum and pretty soon you are trying to turn everything into a casting project :mrgreen:
It is highly rewarding to be able to cast your own parts and pieces.

For casting alloy, forget anything extruded and pop/beer cans.
You want old pistons, cylinder heads, engine parts in general and anything
that was previously cast aluminum.
Wheels are about the highest quality aluminum you can get for the home hobbyist.

CHECK EVERY UNKNOWN PIECE before melting scrap to make sure it isnt magnesium!
vinegar is your freind
Thanks Jim! This is actually a project for a friend for his use but he is going to allow me to use it but I am going to make my own. Nice furnace you have there. I am not really happy with the refractory that I got. I used to build and re-line casting furnaces...BIG ones..and bought the material from my old supplier. It will work fine but it doesn't finish well but that's really nothing but a cosmetic issue, the stuff is great otherwise. I am looking forward to the molding though. And thank you for the links. I never knew home foundries were so popular. As I said, I have relined and built alot of big furnaces, the last one I did held #50,000 of aluminum. My old boss still does it but work has been slow for him as some of his customers have closed their doors. I poured the floor on Tuesday and the walls on Wednesday. I am going to strip it out today and I will post up some more pics. Thanks again for the help! 8-)
Ifyoucantellmewhatthissaysiwillbuyyouabeer.
Jim FLinchbaugh
  • Posts:
  • Joined:
    Thu Sep 01, 2016 11:56 pm
  • Location:
    Kalispell Montana

Its a very fun hobby!
Commercial refractory is way better.
I went home brew, portland cement, fire clay, pearlite and water.
They say it wont last as long as regular refractory but where I live shipping would have killed me
to buy commercial stuff.

Fabrication skills make this hobby much easier as you can build almost everything you need.
There is another youtuber goes by the name sandrammer. He spent 20 some years as a US Navy foundryman.
His videos are far from exciting to watch, and his delivery borders on painful,
BUT he provides some outstanding information if you have the fortitude to take it all in.
It prompted me to search out a copy of the US Navy Foundry manual and it was worth every penny of the 15 bucks it cost me.
exnailpounder
  • Posts:
  • Joined:
    Thu Dec 25, 2014 9:25 am
  • Location:
    near Chicago

Jim FLinchbaugh wrote:Its a very fun hobby!
Commercial refractory is way better.
I went home brew, portland cement, fire clay, pearlite and water.
They say it wont last as long as regular refractory but where I live shipping would have killed me
to buy commercial stuff.

Fabrication skills make this hobby much easier as you can build almost everything you need.
There is another youtuber goes by the name sandrammer. He spent 20 some years as a US Navy foundryman.
His videos are far from exciting to watch, and his delivery borders on painful,
BUT he provides some outstanding information if you have the fortitude to take it all in.
It prompted me to search out a copy of the US Navy Foundry manual and it was worth every penny of the 15 bucks it cost me.
The refractory is from Redline in Chicago and is an excellent product but IMO contains too much coarse aggregate so that's why it doesn't finish well. I stripped out the walls and had a little spalling but no big deal. Right now I have a heat gun in the tuyere and have it up to about 170 to dry it out. I will probably let it sit for a week or so before I cure it. I have no experience in casting, only building furnaces so I am rather excited about that aspect of the process. The guy I am building this for is an absolute genius so between the 2 of us, and the on-line help, we should be ok. My friend works for a drilling outfit so I have 200lbs of powdered bentonite and 500lbs of fine silica sand on the way so I am pretty excited. I will eventually build my own furnace but this one is a great learning experience for me. And you're right, being able to weld and fabricate sure opens up a lot of doors into innovations. Thanks again for your links and I appreciate your feedback! 8-)
Ifyoucantellmewhatthissaysiwillbuyyouabeer.
exnailpounder
  • Posts:
  • Joined:
    Thu Dec 25, 2014 9:25 am
  • Location:
    near Chicago

20170204_150407.jpg
20170204_150407.jpg (39.8 KiB) Viewed 1335 times
20170204_150610.jpg
20170204_150610.jpg (64.91 KiB) Viewed 1335 times
The drying temp and the inside. This stuff dries very unusually and the dark spots will all lighten out to the same color. The spalling is normal and most of the smooth finish will flake off when I cure it to 1880 degrees.
Ifyoucantellmewhatthissaysiwillbuyyouabeer.
User avatar
  • Posts:
  • Joined:
    Fri Oct 02, 2015 8:37 am
  • Location:
    Sydney, Australia

That was quick, you didn't f#$k around !!!!

Very nice job indeed 8-)
Nowadays people know the price of everything and the value of nothing... Oscar Wilde
exnailpounder
  • Posts:
  • Joined:
    Thu Dec 25, 2014 9:25 am
  • Location:
    near Chicago

Thanks Rupes! It didn't require too much weld/fab but most of us are do-it-yourselfers here so I thought it might be interesting.
Ifyoucantellmewhatthissaysiwillbuyyouabeer.
User avatar
  • Posts:
  • Joined:
    Fri Oct 02, 2015 8:37 am
  • Location:
    Sydney, Australia

I think its fantastic. Its one of those things that open up new ways of making things you never thought of before. Who needs a 3d printer that makes useless nicknacks when you can melt down some scrap and pour your own castings.
Nowadays people know the price of everything and the value of nothing... Oscar Wilde
exnailpounder
  • Posts:
  • Joined:
    Thu Dec 25, 2014 9:25 am
  • Location:
    near Chicago

Rupes wrote:I think its fantastic. Its one of those things that open up new ways of making things you never thought of before. Who needs a 3d printer that makes useless nicknacks when you can melt down some scrap and pour your own castings.
:) Thank you!
Ifyoucantellmewhatthissaysiwillbuyyouabeer.
Post Reply