Rusty Bates wrote:
Mr. PG,

Glad to see your web site is finally functional for most of us to
visit. A couple of thoughts come to mind, first that retro-60's floor
you mention is the same type in my own kitchen. The same type of floor
my lovely wife complains about every day of the week. I happen to like
it but that is a different story. :-) The cope and drag box you have
built is nice but have you considered how much that rascle will weigh
once loaded with sand or petrobond? I have a few C&D boxes that size
that I use and the weight is around 80 to 100 pounds easily when
filled. They are gut busters trying to move by yourself to the pouring
area. Might I suggest building a smaller C&D frame to try first as
more than likely your first attempts will be small parts.

I like the floor pattern, but the color just sucks the photons right out
of the air.

Yes, I meant to build a smaller one, but I absentmindedly measured out
the boards for the larger flask that I'll need--I should probably build
the smaller one, too, first.. Still, being 6'2" and 250 lb, I could
probably manage to heave it over semi-gently.

I'm glad to see you are trying to learn a new skill (learning to
casting alumimum and brass is one of the best things I've ever done)
but cheaping out on the crucible design is not the way to go my
friend. The pipe and cap should work (until you get a better feel for
the whole process)if the cap is welded to the pipe. You are correct in
that the clay-graphite crucibles are somewhat fragile and deteriorate
with useage and age. These also require correct fitting lifting tongs
and and good pouring shank to prevent damage to the crucible. Even
then, there is always a chance of breakage during the pouring process.
As others have already mentioned, molten metal of any sort will ruin
your day and other parts of your body given half a chance. I have made
over 300 pours (from 1 to 30 pounds of aluminum at a time on a hobby
basis) in the past 7 years and I still get very nervous when handling
a molten charge. Believe it or not many of us lurkers and posters to
this group do not want see anyone get hurt and there are a few of us
here who have been down the road you now travel. Spend the extra 30-40
bucks and get that cap welded to the bottom of that pipe! As someone
pointed out a few extra dollars spent will be nothing compared to the
medical bills you will get from burnt body parts. Please don't take
this posting as flame as its not meant as such. Good luck!

I had made up my mind to return the nipple, but now I've called around
and nobody seems to have cast iron pots, which was my only other option.
It sounds like you wouldn't recommend me dipping into my vast quantity
of largish steel cans (formerly filled with crushed tomatoes) as a
source of disposable, one-time crucibles.

So let's say, for the sake of argument, that I find someone to weld this
for me. First of all, where should they weld it? If they do the
outside joint, isn't aluminum going to sneak up the inside and crack it
open via expansion and contraction? Will they be able to reach inside
and weld the inside joint?

Second, am I going to be able to drill holes in the nipple itself to
make some lifting holes? I understand that I should be able to drill
steel with a regular twist bit and my father-in-law has a drill press so
the shape isn't a problem, but this seems like a big job for regular
tools.

Hold it, I'm being stupid again. If I'm going to visit a welder, I
could just have him attach some hooks for me. Then I just forge some
hooks from rebar or steel rod and I'm golden.

Anyone here in the southern NH region that can do a little welding for
me in exchange for something?