DIY Ingot molds

[AdamN]

We have a few guys here that are getting some serious weight accumulated and need to do some serious smelting. Here is a little info for those interested in making some ingot molds for yourself.

Any other ideas please feel free to share.........

If you dont have the tools to do any of this check with a local weld shop. They may be able to use scraps on hand. Im not sure what they would charge but compared to buying several Lyman or RCBS molds you may come out a lot cheaper.

First you need material, I have used 3" channel iron scraps, angle iron works well also. I made mine 5" to 6 " long.

I cut a pretty good angle on the ends, nothing critical, the angle lets the ingots fall out easier. I also try to let the ends come up higher than the sides. When you flip the mold to drop the ingots it gives the ingots a little room to fall free.


As you can see in the pics, angle iron or channel iron can be used in for the ends.
http://i64.photobucket.com/albums/h165/aneat/Lead/Ingot1-1.jpg

http://i64.photobucket.com/albums/h165/aneat/Lead/Ingot3.jpg

[AdamN]

You can gang together as many or as few as you feel like lifting when full. Of course it also depends on how long of material you have to use for the ends, no set rules

Ive made them 2, 3 , 4 , or 6 "cavity"

In the second pic you can see the 6 holer that I didnt have material wide enough for the sides so I added some blocks to hold it up so the ingots will fall out easier.

http://i64.photobucket.com/albums/h165/aneat/Lead/ingot4.jpg

http://i64.photobucket.com/albums/h165/aneat/Lead/Ingot2.jpg

[AdamN]

Here is one with angle iron and flat sides.

http://i64.photobucket.com/albums/h165/aneat/Lead/Image035.jpg

[AdamN]

It helps if you use one style of ingot, Both kinds stack very well.

Print out the pics if you like and show them to your local welder, Make sure whatever ingot style you end up with that the ingot will fit in the pot..............


http://i64.photobucket.com/albums/h165/aneat/Lead/ton.jpg

[cohutt]

Thanks for posting this Adam. A friend is the Pres of local technical college, said he his welding/metalworking program is always looking for things classes can make that can actually be used. He said he justed needed me to provide some specs or examples for him to pass on.

This should be plenty- thanks.

[AdamN]

Great idea; I completly forgot about that as a resource. I took a welding class years ago at the local vocational school and there were several guys that would sign up for the class just to use the equipment,

[jawjaboy]

I need me a welder for da shop. Got 220V out there already. And I can weld. Duh.

[AdamN]

One thing I forgot to mention, make sure the weld is on the INSIDE. Ive tried a couple welded on the outside and it never fails that you end up with a hairline crack or gap somewhere. It fills with lead and hardens, then ya gotta beat the hell out of it to get the ingot out.

I try to run a nice hot bead so it lays down as flat as possible, With a good angle on the ends very little or no grinding is necessary.

[copdills]

Thanks for posting this , great information

[yammerschooner]

One thing I forgot to mention, make sure the weld is on the INSIDE. Ive tried a couple welded on the outside and it never fails that you end up with a hairline crack or gap somewhere. It fills with lead and hardens, then ya gotta beat the hell out of it to get the ingot out.

I try to run a nice hot bead so it lays down as flat as possible, With a good angle on the ends very little or no grinding is necessary.


Funny you would post this, especially today.

Today I used the hell out of the smaller molds you sent me. I was running two burners, and didn't have near enough ingot molds.

When I started reading this thread I was going to post that you shouldn't do the inside welds because they stick more. Now I know that the angle iron ingot molds that I put together drop the lead easier simply because of the triangluar shape.

I have fairly big gaps in my homemade molds, but have never had sticking issues. To elaborate on this phenomenon, my welding skills do not hold a candle to yours.

[yammerschooner]

The thing I like the best about the little square molds of yours is the fact that so many of the ingots can fit into the quench bucket before I have to go empty it. The long triangular ones I made don't use space near as efficiently, at least in the bucket.

[Glooooock]

I made some from old bed frame angle iron , they are a foot long . For the smaller 10lb pots a big ingot melts slowly . The 3/4 X 3/4 12 " slides right in besides the valve rod when adding to a half full pot.

[Sky Pilot]

Okay, I'm lazy.
I upend a half dozen pop cans and pour the concave base level full.
I end up with a bunch of lead wafers or lozenges that are a handy size to add to the pot as I am casting.
They don't stack up as nice and neat as the ingots you can throw from your excellent molds, but they work fine for me.

[speedracer211]

dats a lot of lead.

[Pitmaster]

Some of you guys who have made molds can you remember the dimensions (l x w) for the angle and/or channel iron you used and the resulting weight of the ingots?

I would like to make some and dimensions sure would help a neophyte. I figure an 8' piece of either is enough. I'm trying to figure out the length to cut and size to buy. I've got some one who can weld for BBQ.:yesnod:

[AdamN]

PM the Channel I used was 3" wide measured on the outside. If I recall mine are between 4" and 6" long, weigh about 4 to 5 lbs each.

Make sure they put a nice angle on the ends like in the very first pic posted. If they cut them square it will be real tough to get the ingots out.

If youre buying the channel iron ask for any short scraps, you may get a better price.

If you had one 8' piece you could probably make a 6 or 7 cavity mold. Just lay out all the cuts before cutting to minimize any scrap.

The 2 or 3 cavity molds are a little more handy, easier to flip than the 6 holers, duh:biggrinjester:

[BigSlick]

Yeah, but it easy ta outrun lil moulds wit two dutch ovens runnin wide open.

I thank it a be best ta go wit 4-5 8 gang moulds an jus do a lil workin out before they ready ;)

[MakeMineaP99]

2x2 angle and C4 channel.

Pitmaster, I have some of both in my basement, I'll hook you up when I get home next.

[Pitmaster]

I'm not in a hurry but I do plan on smelting that lead I got this fall. I want to be set up to get it done. From the minimal experience I have a quantity of molds are necessary. I'm hoping I can get a 9 quart dutch oven from the Lodge 2nd hand store while going to GA. I have 2 smaller ones but I don't really want to use one of the yet.

http://www.lodgemfg.com/images/logic_dospiral_subcat.jpg

[MakeMineaP99]

I have four moulds I welded up, you can borrow them, plus the materials for more. I got lead that needs to be smelted too, if we can find a weekend when we're both home.

I might weld up some more moulds in a few weeks when I get back to JJB land.

[Pitmaster]

I can be smelting on the 27th if its not raining.

[BigSlick]

Hey PM, you can find some cheap cast iron at Academy Sports.

I got a couple big pots for maybe $15-20 each from them.

Lodge is pretty high dollar on their big pots

Just an option

http://www.academy.com/images/locator/map-05_07_08.gif

[MakeMineaP99]

I can be smelting on the 27th if its not raining.

I'm only going to be in town for 36 hours before I leave from GA.

This travel has got to end.

[RustyFN]

Here is one with angle iron and flat sides.

http://i64.photobucket.com/albums/h165/aneat/Lead/Image035.jpg

Adam I was wondering, it looks like you didn't angle the ends. Do the ingots drop OK with the ends straight?
Rusty

[AdamN]

There angled, but that is a farked up ingot mold to use. If you dont pour just right lead comes rolling out all over the place. I may have been pouring a little fast but the channel iron molds can take it.

I leave it under my casting pot to catch overflows from, the sprue

[Pitmaster]

I'm only going to be in town for 36 hours before I leave from GA.

This travel has got to end.

I know you are getting tired of the travel. I hope it successfully ends soon for you.

Whatever I can do to make our exchange quick for you let me know. The 27th is best since I'm cooking lunch at the IPSCA match on Sunday.

[Pitmaster]

Hey PM, you can find some cheap cast iron at Academy Sports.

I got a couple big pots for maybe $15-20 each from them.

Lodge is pretty high dollar on their big pots

Just an option



I'll keep that in mind. I will be driving through Nashville and Macon.

[jawjaboy]

Y'all still ain't talked me outta making a smelt pot out a dis keg. Ya tried, but ya ain't won yet.

http://i56.photobucket.com/albums/g194/jawjaboy/IM000290.jpg

[BigSlick]

How you gonna dip out from da bottom ?

You gonna hafta put a valve on it or cut it in half (cross ways)

[jawjaboy]

Si, Amigo.

[AdamN]

Just get it full of lead and tap it, its a keg. Whats the worst that can happen???? Right???:yikes::43:

[Pitmaster]

Got a quote on some 3" channel to make some ingot molds. 20' piece was $97. Welding and cutting to make was going to be $57 per mold. Can't remember exact configuration but I thought that was expensive and am going to pass. I do have some decent muffin tins that work. Smelted 90lbs yesterday with them and a RCBS cast ingot mold. I'll keep poking around at the sales and thrift stores.

[MakeMineaP99]

I'll take care of you. If you can get me access to welding equipment in South Bend, I'll even weld some up for you, free.

I won't be able to do this at the end of the month, but I can probably do it on my week off at the end of Oct.

[Oreo]

Just get it full of lead and tap it, its a keg. Whats the worst that can happen???? Right???:yikes::43:Anyone here ever just straight up knocked over a big vat of molten lead?

[AdamN]

I think Freak either spilled or had a pretty big eruption from getting some water in the pot.

Ive heard of a couple guys having aluminum pots fail and empty out.

Thats one reason to wear long pants/good heavy shoes, stuff happens.

Dont smelt in a thong and flip flops

[freakshow10mm]

Yup. Water in the pot was a big lead dragon with a hard on. Scary.

[Pitmaster]

I'll take care of you. If you can get me access to welding equipment in South Bend, I'll even weld some up for you, free.

I won't be able to do this at the end of the month, but I can probably do it on my week off at the end of Oct.

The welding is not the hassle so much. It was the price of steel. I may go see what I can scrounge up at a scrap yard.

[yammerschooner]

The tinsel fairy shot just enough liquid lead down one of my welding gloves a few weeks ago to keep me on guard. I only have one scab that is still healing over.

I probably wouldn't have gotten burnt so badly if I would have either worn long sleeves or taken the gloves off. Instead I decided to simply man up and deal with it in the interest of not spreading the hot and keeping up with what I was doing.

Yes, I know I should have had long sleeves on.