Iron Melting Cupola Furnaces for the Small Foundry

Iron Melting Cupola Furnaces for the Small Foundry
Stephen D. Chastain | 2000-07-01 00:00:00 | Stephen D. Chastain | 128 | Engineering
Complete plans and operating instructions for a 10 inch diameter cupola that melts 330 pounds of iron when powered by a shop vac. Also included are plans for a high pressure blower that will increase the output to 660 pound of iron per hour. All can be built for little cost, mostly from scrap.
Reviews
I won't re-iterate the previous good reviews on this book. However, there's one review in which the author mentions the cupola furnace is "small". A furnace that melts upwards of 600 pounds of grey iron per hour is nothing to sneeze at. And, the furnace can provide approximately 200 lbs of iron per tap. That's more than one man can handle. Besides, he gives you all the information necessary to build whatever size you want! As for the requirement of welding equipment, lathe, etc. - if you don't own or have access to this equipment and the knowledge to use it correctly, you shouldn't be attempting to build anything of this sort to begin with. This is an excellent book written by someone with the practical knowledge that uses the furnace the way an above average machinist/mechainc/repairman would. This book will give an individual an opportunity to make him/herself an excellent living.
Reviews
This is a nice book on how to build a realatively small cupola for melting iron. It is well written, and he has a couple of pictures in the book. This is not a beginners furnace however and it requires a cutting torch, welder, and a small lathe for a couple of parts. Also, iron in general is rather dangerous for a beginner, so start with lead or Aluminum. For info on melting aluminum, check out ...
In general, I would recommend this book for reference if you are a beginning foundry person, but if you are really serious, go for it.
Reviews
Stephen D. Chastain's book Iron Melting Cupola Furnaces for the Small Foundry is not a rewrite of information from the past but Steve has designed, built and has in use a cupola furnaces suitable for casting those obsolete iron parts you can no longer find or making proto types allin your back yard (But only if you have vary good neighbors thatlike you a great deal!). Steve's book has a good mix of practicalinformation and theory. Using his little book, two of my friends and I have taken the detailed information presented and have fabricated a working coke burning cupola furnace (including the blower). I would not have started the project without his book. Steve also gives detailed information on running the furnace to melt iron. His book now finds its self dog-eared, highlighted, annotated, and returned to often - it is well worth the money.

Brian
Reviews
Stephen D. Chastain's book Iron Melting Cupola Furnaces for the Small Foundry is not a rewrite of information from the past but Steve has designed, built and has in use a cupola furnaces suitable for casting those obsolete iron parts you can no longer find or making proto types all in your back yard (But only if you have vary good neighbors that like you a great deal!). Steve's book has a good mix of practical information and theory. Using his little book, two of my friends and I have taken the detailed information presented and have fabricated a working coke burning cupola furnace (including the blower). I would not have started the project without his book. Steve also gives detailed information on running the furnace to melt iron. His book now kinds its self dog-eared, highlighted, annotated, and returned to often - it is well worth the money.
Reviews
Steve Chastain has written a modern, comprehensive "how to" guide on the construction and operation of small cupola furnaces. I have built and operated a 10 inch cupola furnace using his book as the major reference. The chapters include:

1) Cupola theory and design considerations

2) Building a 10 inch cupola

3) Cupola operation

4) Air supply and blowers

5) Designing centrifugal fans

6) Construction of centrifugal fans

7) Construction of a Pitot tube and manometer

8) Calculation of Air Flow

9) Additional Cupolas based on the 15 inch shell

10) Oxygen enrichment

11) Purchase of Coke

12) Conclusion

Appendix:

Suppliers

Airflow through pipe

This 128 page book is a treasure trove for the amateur foundryman. It is absolutely packed with accurate information. I have operated a small propane fired crucible furnace for several years and needed larger volumes of cast iron. Without any prior experience I was able to build a functioning 10 inch cupola furnace. I made mistakes along the way. The two most glaring were not following the blower selection and cupola operation exactly. You can not take shortcuts, period. I was intimidated by the thought of building a powerful blower and tried to substitute insulation and dust collection blowers. It didn't work. Re-reading the book explained why in eloquent detail (with straight forward math to back it up). I had never built and balanced a blower before. Following the book I had a blower that worked the first time and exceeded design specifications. I picked the wrong size coke for the furnace and produced a disappointing quantity of cast iron as a result. Using the correct size coke and following the instructions remedied the situation. If there are limitations with this small book it is that the author expects that you will read and comprehend the book before you rush off and start building the furnace. Do not take short cuts. This will ultimately save you time, money and frustration.

I can recommend Mr. Chastains book with enthusiasm.

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