Many people are put off casting metal at home because they perceive it to be dangerous, difficult and expensive to set up. Taking each of these points in turn: Dangerous? Yes, casting metal can be dangerous. This is particularly true for the higher melting alloys such as brass and cast iron. However, the melting point of aluminium alloys is only around 650 degrees C. This is about the same as silver solder. Provided sensible precautions are taken during melting and casting and provided protective clothing is worn, then the dangers can be greatly minimised. Difficult? No, metal casting is not difficult. It is, in fact, very straightforward to make simple patterns and castings. Expensive? Of course you can spend a fortune getting kitted out with a furnace, a burner, a gas bottle, crucibles, tongs, temperature measuring equipment and protective clothing from commercial sources. But with a little improvisation all these things can be easily made or acquired. Remember too that the costs are offset by the fact that aluminium is a ubiquitous metal and that scrap aluminium can usually be obtained for free.
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