How to Melt Aluminum With a Torch

Lay two courses of brick in a square to set up two sandboxes, 6 to 8 inches deep by 18 to 24 inches square, outdoors. Position the sandboxes next to each other and fill them with sand. Build the sandboxes away from flammables.

Set a graphite and clay crucible in the sandbox, burying it 1 to 2 inches in the sand. The sand both absorbs excess heat and creates a stable base for the crucible.

Set the casting molds in the second sandbox.

Wash the aluminum pieces with a grease-fighting detergent to remove flammable contaminants. Dry the aluminum thoroughly. Compact the aluminum to its smallest possible size by striking cans or other hollow pieces with a mallet.

Remove all your jewelry including rings, watches, bracelets, earrings and necklaces. Put on welding gauntlets, a welding face-shield, a leather welding apron and welding-approved safety shoes. Tie your hair back and tuck it under a leather skullcap.

Place the aluminum into the crucible, filling it no higher than halfway. Turn the knob on the side of the propane torch slightly to allow propane to barely escape. Light the propane torch with a striker. Turn the knob on the torch to increase the flame size and wave the flame over the aluminum until the aluminum melts. Add more aluminum pieces to continue the melting process.

Insert a pyrometer into the aluminum and monitor the temperature. Continue to heat the aluminum until the pyrometer indicates that the aluminum is above 1,380 degrees Fahrenheit and therefore in a pourable state.

Skim impurities off the top of the molten metal with a specialized skimmer and set to the side to cool for later disposal.

Lift the crucible with crucible tongs. Tilt the crucible with a crucible shank and pour the melted aluminum into the mold.