Tin has a relatively low melting point so it's easy to shape to your liking. However, melting lead must be done with extreme caution and care as this material can cause serious burns, fires and poisoning. Work in a safe area, wear safety clothing and equipment, and keep children away from the area. After that, heat the tin until it melts, remove any residue, then pour it into the mold as desired and let it cool before removing it.
Step
Method 1 of 3: Wearing Safety Equipment
Step 1. Work in a dry, ventilated and safe area from the risk of fire
You should only melt lead in a well-ventilated area at least 3 meters away from combustible materials as this process can create toxic fumes and large fires. Outdoor areas with dry earth, sand, or concrete floors are good choices.
- Do not melt lead in the room, especially if the room is connected to the inside of the house. The risk of exposure to lead fumes, lead dust and fire is too dangerous.
- Keep children, pregnant women, and mothers who are breastfeeding away from the area. Exposure to lead fumes or lead dust is very harmful to fetuses, toddlers, and children.
Step 2. Choose a heat source and special equipment to melt the lead
Cast iron skillets, aluminum spoons, and aluminum spoons are all good tools for melting tin for personal use. However, make sure the appliance is only used for this purpose – never use it for cooking! Since new tin melts at 327 °C, you will also need to prepare a safe heat source. Some of the most popular options are:
- Gas torch for cooking. This thing is relatively safe and easy to use by anyone. However, using this tool makes you only have one empty hand during the heating process. You can buy gas torches for around IDR 200,000 to IDR 500,000.
- Propane powered burners; as used on the stove to fry chicken. Chicken fryers usually have a burner attached to a permanent stand so you can easily place the tin melting pan on top. However, the heat in this tool is more difficult to control than a gas torch. The price ranges from IDR 500,000 to IDR 1,000,000.
- Electric melting pot. This tool is specially designed to melt metals such as lead and does not use fire so that the melting time is longer. This tool is usually sold in the price range of Rp. 500,000 to Rp. 1,000,000.
Step 3. Wear respiratory protection and fire protection equipment before melting anything
There are some major risks when melting lead, such as fire or high temperatures, molten metal, lead fumes, and lead dust. Don't take your safety for granted! Personal safety equipment should include:
- Respiratory protection mask when melting metal such as lead.
- Eye protection or face shield for better protection.
- Thick leather gloves designed to withstand exposure to hot temperatures such as when you melt metal.
- Long-sleeved clothes, long pants, and sturdy shoes. Also, consider wearing disposable protective clothing to prevent lead dust from sticking to your clothes and body.
- A hat, protective net, or other device to keep your hair from fraying near heat sources.
Method 2 of 3: Melting the Lead
Step 1. Place the tin chips in a cast-iron skillet or electric melting pot
Estimate the amount of tin needed by weight, then add the tin to the pan by adding 20%. You'll need a larger amount as some of the lead is reduced due to residue and hardening on the pan and tools used. However, don't fill the pan more than 75% of its capacity for safety reasons – use a larger pan if necessary.
For example, you can melt 2.2 kg of lead flakes to fill a 1.8 kg mold once the process is complete
Step 2. Heat the pan directly until the tin is completely melted
If you are using a gas torch, turn on the appliance according to the product instructions and move the flame back and forth over the tin surface placed on the pan. If you are using a propane burner, use the appliance according to the instructions and use high heat to heat the pan. If you are using an electric melting pot, plug in the power cord and adjust the heat according to the instructions on the product package.
Melting times vary widely based on the heat source, the residual content in the tin, and other factors. In general, this process takes 5 to 10 minutes
Step 3. Remove any floating residue (“dross”) with an aluminum scoop
Keep the heat source lit below or above the molten lead and watch for dross floating to the surface. Use a scoop to remove the residue from the surface of the molten tin. Put the lead residue in an aluminum container – large coffee cans are a great option.
- Choose a container with a lid that you can throw away when you're done. This will limit the amount of lead dust that emerges from the drying dross.
- Make sure the scoops and disposable containers you use are dry before using them. Melted lead can cause the water droplets to evaporate immediately and cause the lead to spray at you.
Step 4. Stir in 1 or 2 tea light candles, if desired, to “thin” the tin
This refining step is optional for most in-house tin melting processes. This process creates a lot of dangerous smoke and fire on the surface of the melted tin. If you don't need pure lead, just skip this step.
- If you choose to thin the tin, continue heating the pot or pan. Place the tea light candle on the scoop and stir until it is combined with the melted tin. Keep stirring until the smoke subsides and the fire comes to the surface. After about 1 to 2 minutes, the smoke and fire should be gone.
- For a purer result, insert the second stick of wax after it with a rake to pick up and remove any residue left by the first wax.
Step 5. Put the lid on the disposable container and throw it away when it cools down
When you have finished removing the residue from the surface of the melted tin, place a cover on the disposal container. Make sure you wear personal protective equipment as it is very hot! Once the exterior of the container is cool to the touch, place it in a special garbage bag to place outside the house for local cleaners to pick up.
Method 3 of 3: Casting and Casting Tin
Step 1. Scoop or pour the molten tin into the mould
Turn off the heat source and work quickly to get the melted tin into the mold before it cools and hardens. If the cast-iron skillet has a spout on the lip, you can try pouring the metal directly into the mould. This process may be easier to do by scooping out the lead with an aluminum spoon and pouring it into a mold.
- You can use pre-made molds to make small items like fishing rod weights, or you can use an aluminum cake pan to make ingots for later use.
- Gently stir the mold after inserting the tin to remove any air bubbles inside.
- Even if you are wearing heat-resistant gloves, do not insert your hands (or other body parts) directly into the mold opening. Hot gases from molten lead can cause burns.
- Make sure the mold is cool before putting the tin in it.
Step 2. Allow the tin to cool in the mold for 10 minutes
The tin will harden after 2 to 3 minutes. To be safe and get the best results, wait up to 10 minutes before trying to remove the lead from the mold.
Step 3. Remove the tin from the mold once it is cool to the touch
Tin doesn't stick well to other metals so you shouldn't have a hard time removing it from the mold. Be sure to wear gloves even if the print is cold to the touch. The lead inside may still be hot enough to injure you.
- For double-sided molds used when making items such as fishing rod weights, remove the securing bolts first. The results of the tin mold will immediately come out.
- Simply turn the aluminum cake pan over and tap it on a firm surface to allow the tin ingot to pop out.
Step 4. Clean the body, clothing, equipment and work area to remove lead dust
Use a dry and wet vacuum cleaner with a HEPA filter to remove lead dust that has accumulated on your equipment or work area. Take off your clothes in the garage or elsewhere outside the house. If you can, put clothes in special bags and wash them separately. Take a shower and wash your hair and body thoroughly.
- Exposure to lead dust can cause serious health problems and interfere with the brain development of fetuses, toddlers, and children.
- Melted lead that spills and hardens on the work area floor can be scraped off with a chisel or a flat-head screwdriver.
Warning
- Do not try to melt tin in a container made of pure white tin as this material has a lower melting point than tin.
- Melting lead or other metals at home is a dangerous job. So, do this very carefully.
