Check out my website for details on how the foundry was built: http://www.budgiemetalworks.ca
This is the first casting in my homemade aluminum foundry. Approximately 5 lbs of aluminum was poured here which took about 2 hours to melt. The furnace draws 20A on 220VAC.
The element was custom made for me at a pottery kiln shop, the body of the furnace is made from firebricks and commercial cast refractory. The tools for handling the crucible were made by myself. The amperage controller is sitting on the pink foam on the floor, I'll be enclosing it properly but wanted to try it out first. The final furnace took about 6 months to complete, working on it every couple weekends, and I expect to get a lot of use from it.