How to cast with aluminium?
The part i wish to remake is a headlight bowl off a rare motorcycle and a side panel. Both parts are in plastic.
Answers:
You could sand cast it or use the lost wax process.
Many years ago we cast statues using aluminium and we had no problems melting and pouring.
buy some industrial epoxy resin. Use the current part as a mould to create both a female and a male part of a tool so that you have two pieces which when placed together create a cavity in the shape of the headlamp you are trying to replicate. Then it is just a case of heating the aluminium and pouring it into the cavity. Let it cool a a wonderful new Aluminium headlamp
Big problem with that. Aluminum doesn't melt. When it reaches it's melting point, it vaporises.
"castrol75" has a good answer for you. Also, look up "lost foam tachnology". If you replicate your headlamp bezel in styrofoam and pack that into sand, the pour your molten aluminum into that, the aluminum will disolve the foam and fill the cavity. Also, PLEASE remember, for your safety, you cannot have ANY liquids present when working with molten metals! Not even damp sand. Be careful! (a can of soda or a bottle of water spilled/dropped into molten metal can level a factory building!)
Dont even think about it; the fumes will kill you.
I'd recommend a book. Start with this one:
http://www.lindsaybks.com/dgjp/djgbk/cha.
And if you want an electric furnace, the first book on this page:
http://www.lindsaybks.com/dgjp/djgbk/fou.
They're very interesting - I have read them, but not attempted to use the material in them yet myself. They cover everything from how to build a furnace to melt aluminum to the art of making molds from sand. You can probably use the original parts as patterns, in fact.
Take the bits to a non ferrous foundry, and tell them to replicate the pieces. It's not a 'back yard' job, I promise.
There are plenty of people out there who cast aluminum in their backyard. Aluminum does melt - not vaporize. Anything involving molten metal will release fumes (including soldering) and should be done in a well ventilated area.
The big issue you'll run into is the need to rig up quite a bit of equipment and chances are your first couple tries will produce less than professional looking results. You can find more info on backyard metalworking at: http://www.backyardmetalcasting.com/.
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