Full Aluminum Cast Locust Bench

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Project by ErikF posted 05-20-2017 10:41 PM 961 views 1 time favorited 6 comments Add to Favorites Watch

Thought I would try some lost foam casting to make a bench.

I cut a 1” dado around two loose black locust boards and the filled the dado with Styrofoam. After that I rigged up a base and glued it to the foam in the dado.

The first bench I tried failed due to using loose sand, second attempt worked better since I mixed up a large batch of green sand. Biggest problem is packing the sand around the legs since the foam isn’t very rigid.

Second issue is handling this much melted aluminum. I’ll have to build a new pouring handle prior to the next try.

It was a fun project that was able to be knocked out in an afternoon. Second bench turned out well enough to have as a useful piece of shop furniture…it should also last a long time since it’s a combination of two materials that don’t tend to breakdown.

-- Power to the people.

6 comments so far

View DocSavage45's profile


8379 posts in 2682 days

#1 posted 05-20-2017 11:51 PM

Eric, creative and innovative. I’m thinking maybe you could cast the alluminum and then secure to the bench eliminating some blow out?

-- Cau Haus Designs, Thomas J. Tieffenbacher

View Don W's profile

Don W

18524 posts in 2407 days

#2 posted 05-21-2017 12:07 AM

those are not locust boards, they are locust planks! You should be good to set the D9 on there when you need to work on it!

-- - Collecting is an investment in the past, and the future.

View Jerry's profile


2457 posts in 1488 days

#3 posted 05-21-2017 02:28 AM

Really interesting.

-- There are good ships and there are wood ships, the ships that sail the sea, but the best ships are friendships and may they always be.

View Andre's profile


1497 posts in 1646 days

#4 posted 05-21-2017 02:32 AM

Ahh, to be young and ambitious! If only I new 30 years ago what I know now? Great project.

-- Lifting one end of the plank.

View shipwright's profile


7783 posts in 2637 days

#5 posted 05-21-2017 03:14 PM

Looks like fun Erik. For larger castings I used to use a molasses valve. I was pouring lead for keels but it should work as well for aluminium. It also eliminates the need to move any molten material by tipping or ladling. I was able to do a constant pour of 6,000 lbs.
More details in this blog.

-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fibreglass trees.

View ErikF's profile


574 posts in 2083 days

#6 posted 05-22-2017 11:43 PM

those are not locust boards, they are locust planks! You should be good to set the D9 on there when you need to work on it!

- Don W

No kidding, right? I want everything locust these days

-- Power to the people.

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