Refractory Cement For Your Foundry Furnace can be a REAL B*TCH!

If you don't get the recipe just right, you could have the walls crumble at full temp, or melt into a pile of glass and clay.

I'm hope in the next few weeks to have all the pages written to go along with the pics. I've taken. My goal is to save you some time and possibly prevent a serious accident.

Lawyer BS to cover my Butt.

WARNING!!!: You got a brain... USE IT! Building and working with a foundry furnace is "NOT" child's play. It can be very dangerous and if 'you' screw-up don't come crying back to me! If you don't know what you're doing and didn't take the time to read and study all the safety procedures that are available on the net, as well as your local library, and you get hurt that's your problem. You are responsible for yourself and your own actions and safety.

--- "NOT ME!" ---

Bare Bones basic Refractory

Method #1

• 4 parts Perlite Standard 2.0-5.0mm,
  (This is PURE - NO ADDITIVES!)
• 1 part Fire Cement rated at least 1400° or higher.
  (For brass at least 1800°)

Let dry at room temp for several days.
Then bake at low temp (225/275) for several hours and no
smoke or steam. Then let it cool down completely and
repeat at a little higher temp. each time till it's fully baked in.

Method #2

• 1.5 parts Portland cement (This is "NOT" a ready
  mix stuff. This Pure Cement - no rocks or sand)
  


• 2 parts silica sand (The same stuff you use for your
  GreenSand)
  


• 1.5 parts perlite (Pure - not a blend of other things
  meant for plants. "NOT" Vermiculite either!)
  


• 2 parts fireclay or Well drillers mud (Bentonite Clay)

You want to mix the dry parts thoroughly, it will take a while
for the clay to bond to the sand. You could use a cement
mixer/rolling tumbler/vibrating tumbler, but this is 'ONLY'
for the dry parts, it's way to thick and gooey once you start
adding the water.

IMPORTANT: Add as little water as possible. You don't want
it to be soupy you want more in the line of a moist cookie dough.

Let dry for several days, (Even a week for bigger furnaces)
then fire up the furnace on as low a setting as possible.
(Remember "LOW AND SLOW"!)

1st. burn for 15 minutes - let it cool down - COMPLETELY COLD!

2nd. burn for 30 minutes - let it cool down - COMPLETELY COLD!

3rd. burn for 45 minutes - let it cool down - COMPLETELY COLD!

4th. burn turn up the heat and if no smoke or steam comes out
    you're ready to melt metal.

Here's your Safety Warning!
"IF" you try and fire up your furnace to a high heat BEFORE it's completely dry.... IT MIGHT EXPLODE!!! You've been Warned!

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