From Roadside Trash to Stacked Treasure -- turning scrapped electrical wire into aluminum ingots
Sea Level Made Sea Level Made
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 Published On Mar 14, 2024

This was quite a session. I picked up a whole tangle of wire from the roadside to see what I could maybe scrap or melt. After unwinding the three different cables, I discovered one was useless, but the other two were aluminum sleeved with an aluminum wire core. I cute them into manageable lengths and set about stripping.

Stripping the outer layer of plastic off the wire was easy - just use a utility knife to slice and it peels right off. Then I tackled opening each aluminum sleeve to try and get at the insulation. That soon proved to be pointless. The last hope I had of melting these down was to see if the insulation layer would burn and leave the aluminum to melt clean. I tested a piece and it worked. We were in business!

This video shows the process of melting sections of thick aluminum sleeved insulated wire down into handpoured cast aluminum ingots. It took a few hours, but I got that batch done and managed to convert some scrap metal trash into treasure by the end.

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TLDR for the gagoogling and algorhythmness:
Relax and watch this satisfying video full of asmr sounds from a mesmerizing fire created by a propane furnace / forge in my backyard foundry. You will probably see melting metal and trash turned into treasure as I add scrap metal to a crucible and turn it into handpoured handmade ingots or other custom shapes. Usually the metal melting is aluminum cast into bars, but I am working my way toward silver for the bullion stackers. Call me the poor man's BigStackD, if you will. Enjoy!

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