Here is what I have done in casting so far (unfortunately no pics). Aluminum and brass can be melted down in a very simple home made furnace that runs on charcoal, and a blow dryer (no kidding).
You need a 5 gallon steel pail, some play sand, and fireclay (available from grainger as furnace liner refractory in dry powder form). The rest is easy and with a nights fire run inside it will bake to a relatively hard (fire brick hard) liner.
I made a crucible from a 4 inch diameter steel pipe, and it works great. I just fill the thing up with whatever scrap I am going to melt, and fill the rest of the furnace with charcoal and light it off. Takes about 15 minutes to melt 5 to 6 pounds of aluminum, and brass takes a bit longer.
There are many good, cheap books on the subject, and all are worth more than the info you get from them. I got mine along wiht alot more from Lindsaybks.com and am about to get one on a propane fired forge for about 10 bucks I think.
I bought into the whole thing for my motorcycles, but I have thought of alot more uses for the furnace with the knife making. I have thought about ornate bolsters and gaurds, and this would be one way to accomplish all of that without a ton of work.
If you would like more info from me you can email me at
dns@knology.net.
Doc