Small foundries that are available for purchase online or that are built at home tend to work best for melting aluminum, as aluminum melts at a relatively low temperature. Premade foundries are typically heated with propane, so you will need a tank of propane in addition to the foundry.
Pick a spot that is not near anything flammable, such as dry grass or building materials that could catch on fire. There will be fumes created when melting metal, so it’s important not to do it in a confined area.
Wear shoes that have closed toes and a welding jacket, which will protect your chest and arms.
If you are using a premade foundry, follow the directions that came with it exactly. The directions should instruct you about the proper propane pressure to use and what safety precautions to use, in addition to other details.
Once the metal is completely melted, it will glow bright red but there may be some dark spots where impurities are burning off.
If you want to mold the metal into a specific shape, you will need to buy or make a metal casting mold.
Welding tipped torches come in a variety of sizes. Large ones that use full size oxygen and acetylene tanks are used for welding pieces of steel. Small oxyacetylene torches are used for melting small pieces of soft metal, such as gold and silver used for jewelry making. The small torches are typically attached to small oxygen and acetylene tanks.
You will want an oxygen tank that is at least twice the size of the acetylene tank.
If you want to work on a raised surface, instead of on the floor, you will need to use a metal table or supports that won’t burn or melt. There are specialty welding tables made of thick steel that are made specifically for this kind of work.
Once lit, adjust your oxygen and acetylene levels to create a small blue flame inside the larger orange flame.
You can cut metal into a wide variety of shapes by melting it with a torch. For instance, you can make a decorative shape or a replacement part that you need.
