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Question:

How much casting sand?

I have to make a couple aluminum ingot molds and wasn't sure how much casting sand I neededAlso since the shape of the bricks is really simple I wasn't sure if I needed a two part mold reallyAny advice?

Answer:

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With aluminum you don't actually need casting sand for molding ingots - you need a wooden shape of about the right shape to press down into the damp sand that you pack into shapeCasting sand is finer than the playbox sand sold in hardware stores and will give a smoother surfaceThis link shows my plain sand box (being used for a second purpose in the picture, my casting sand frame, and some other stuff including the sand pounding tool I made which I also push ingot shapes into the sand (I also have some 2x2x4 ingot models tapered on the side) and way down in the iron pot melting aluminum is one of the ingotsIf open faced, the ingot will have a rounded top, like water in a filled glass has curved edges and for the same reasonAs for how much, I would plan on 2 of sand in all directions from aluminum if you are in a wood box or a hole in the ground - just to give enough sand that the wet stickiness has enough strength to hold together as it dries out under the heat If your ingots are 2x2x4 like mine, then a box 6x6x8 would be needed for 1 ingot - which is wasteful - add 4 for each additional ingot sideways - I do 3 or 4 in the sand box shown.

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