Gary, we are really glad you finally posted this thread. I guess no one could be more anxious than you were, but we think you're well on your way now and your progress should go at an exponential clip now that you have achieved melting and pouring. For the little help we were able to provide, we expect nothing in return...........well a nice little Lion Mortar similar to what Max Caliber posted about a year ago would be nice! Seriously though, it has been a real pleasure helping out and seeing your dogged determination to see this project through.
The following are a few pics of Gary's Backyard Bronze Foundry. Gary has done a tremendous amount of research, even before buying the first piece of equipment. He is on a mission. Mike and I are sure of his success in casting high quality bronze cannon.
Mike and Tracy
PS I neglected to get a photo of the dross consolidating powder being added. A long column of white smoke rises from the furnace as this chemical attracts the impurities to the surface of the melt, as it is stirred into the molten metal, then the dross containing these impurities is skimmed off with a large 3/16" thick steel spoon with a 2.5 foot handle.
This shows the 20 lb. propane bottle, delivery hose and the venturi device that mixes the fuel and air and delivers it into the furnace along the wall to achieve a swirling motion of the fire and heat to surround the melting crucible. The furnace weighs about 200 lbs.
Crucible handling equipment here; in the back are the crucible tongs which work like ice tongs and allow the foundry worker to grab and then lift the crucible from the furnace. In front is the pouring cradle which holds the crucible securely, ( x 20 is a sliding keeper that holds the crucible in the cradle) and has two handles at one end for rotating the cradle during the pour over the mold.
Essential safety clothing.
Pure copper electrical wire and mini ingots of tin melt in the intense heat of the propane furnace.
A small quantity of de-gassing powder is lowered into the liquid bronze. The stainless steel dipper is about two feet long and L-shaped.
Looks pretty nasty from the top, but it's shiny, tough, very tough bronze underneath. Standard 1 lb. lead ingot molds were used. Never used for lead, they were new and clean.
This shot shows an empty furnace after the pour and the three pieces of fire brick which provide a stable, centered, support for the crucible's bottom. You want some heat 'under' the crucible during liquifaction.