- 1). Place casting sand inside of solid wood box or container (any solid container will do) until the container is half full.
- 2). Pack the sand down with a flat tool like a trowel or tamping tool until it is hard and all the air pockets are pressed out of the sand. Add water to the casting sand if the sand will not pack down sufficiently.
- 3). Insert a disc shaped piece of wood into the sand to form one half of the pulley. Use a disc of wood that is the exact size of the pulley you are going to produce. Then remove the disc leaving just the impression of the disc in the sand.
- 4). Insert scrap metal like pieces of aluminum siding or steel framing into a metal furnace pot (make sure it is unplugged). Turn the metal furnace on and set it to high. Wait until the metal is fully melted inside the furnace pot. This will take between 15 and 25 minutes depending on your furnace.
- 5). Remove the metal furnace pot using a pair of iron tongs and a heat glove for added protection. Or, use the provided heat tongs that come with your furnace to remove the melted metal. Pour the melted metal into the sand mold by tilting the tongs and furnace pot. Let this cool for several hours and then remove the solid pulley half.
- 6). Repeat steps 1 to 3 to create another half of the pulley. Then drill out the center of each pulley with a 1/4 inch carbide drill bit and power drill. Attach the two halves using a 1/4 inch bolt, washer, and hexagonal nut. Tighten the nut with a socket wrench.
SHARE
