Foundry, forge or kiln propane burner Instructions
Copyright © 2013 by: Lionel Oliver II — www.BackyardMetalcasting.com
This item is not for sale to minors. Using a gas burner involves danger from extreme heat. This burner produces flames and hightemperatures which could result in injury, loss of life or property damage. Burns and unwanted fires may result especially fromcareless usage. Safety precautions should ALWAYS be followed. You are responsible for using this item safely and keeping
the item in safe working order. Use of this item is at your own risk. Neither the manufacturer, the seller nor anyone affiliated withthe manufacturer or the seller is responsible for any damage or injuries, no matter how minor or major that may result from theproper or improper use of this item. By purchasing this item the buyer agrees to the above terms and to be solely responsible forhis or her usage and the usage of anyone who uses this item with or without the buyer's consent. If you do not agree to theseterms DO NOT buy this item. Propane gas can accumulate and ignite explosively when used incorrectly. Propane fumes cancause suffocation from inhaling them. If you have any questions about properly using or storing propane or other fuel gasses contact your nearest gas distributor. Safety should ALWAYS come first!

Setting up the components
Setting up the propane components is fairly basic. The components necessary are; the propane tank, regulator, propane hose, attachment fittings and an optional attachment is a propane pressure gauge.
Most hobbyists use the propane tank size designated as the 20-pound tank. These are commonly usedfor gas barbecue grills. One of these tanks can be expected to give about 6 hours worth of melting time. Butthat is an approximation since several variables effect the time. Such as burner size, pressure setting, etc.
Larger propane tanks can be used as well.
The propane regulator is essential for safely using the “self-aspirated” burner design. Self-aspirated simply means that the burner provides it’s own combustion air as compared to a “forced-air” burner which requires an air blower. Another name for the self-aspirated burner is “atmospheric burner” because atmospheric pressure pushes air into the burner as a result of the vacuum effect created by the gas jet.
Only high pressure regulators will work with self-aspirated burners. And the regulator needs to be adjustable. The small regulator used on most gas grills will not work because they provide the propane at alow pressure (about 5 ounces). The pressures needed for these burners range from about 5 to 25 pounds(PSI).
There are several sources for these regulators.
Plumbing and welding supply stores will most
likely have them but at a high price. However
they will probably be high quality units and possibly contain a built in pressure gauge.
Lower cost high pressure regulators may beavailable from restaurant supply stores or camping catalogs. Some high output gas appliancessuch as cook stoves and turkey fryers requirethem. If you have trouble locating them locallythere are sources for them on the internet andsome are listed in the “suppliers” section of thismanual.
The propane hose should be 10 feet long forsafety. The black rubber propane hoses should beavailable at a fairly low cost. Custom lengths canHere is a propane tank and an adjustable high pressure regulator isoften be fabricated by the seller. Since propane
screwed into the valve with the propane hose extending to the left.
dissolves some types of rubber it is not safe touse hoses designed for other gasses such as natural gas or acetylene.
Only hoses specifically labeled for propane should be used. The ends of the hose should have brass fittings that match common pipe sizes. 1/4" nominal pipe (NPT) size threads are very convenient. Sources forhose are also listed in the suppliers section.
A propane pressure gauge is convenient for when you want to know exactly what pressure your burner isrunning at. However it is not necessary.
The attachment fittings used will vary depending on the way you choose to attach the burner to the propane hose. Two methods are illustrated below.
Both methods begin the same. The adjustablehigh pressure propane regulator is screwed into
the valve of the propane tank. The gas outlet ofthe regulator is where the pressure gauge will beinstalled (if you choose to use one). If not the propane hose will screw into this spot.
The way the hose attaches to the burner iswhere the two methods differ. In the first method
the propane hose has the end fitting (usually a3/8” attachment) cut off and replaced with a brass
hose barb that matches the inner diameter of thehose. It’s secured with a stainless steel hose
clamp. 1/4” male threads are on the fitting. If
your hose already comes with 1/4” male threads
on each end then the hose barb is not necessary.
These threads screw into the 1/4” x 1/8” reducer
There are multiple ways to attach a propane hose. Here are twoon the burner’s fuel jet pipe.
common ones.
The second method uses the hose barb
(already installed) to screw into a ball valve which is used for a quick shut off. The valve screws onto a
short section of pipe called a “nipple.” The nipple then screws into the 1/4" to 1/8" reducer coupling on theburner.
The convenient thing about having the ball valve at the burner is that you can open the propane tank’svalve and keep the ball valve shut. Then when you’re ready to fire up the furnace you can slowly open thisball valve to release the gas while keeping the propane tank safely away from the furnace.
A third way to attach the burner that I have had success with is to use a quick coupler attachment. Thesecouplers are designed for air tools but I’ve found them to work well for the propane burners. However as aprecaution, it is necessary to check that any rubber seals in them do not degrade and leak from the propane.
To use the quick coupler, the hose barb (attached to the hose as described previously) is screwed into thefemale half of the quick coupler unit. The male coupler fitting, which is the smaller part is screwed into
the burner’s reducer fitting. This is illustrated in the next photo.
Igniting the furnace, forge or kiln
With the lid raised prepare to light the furnace.
An easy way to do this is to crumple a piece ofnewspaper and drop it into the furnace in front of
the burner. With the lid still up off the furnace
slowly open the gas valve allowing gas the enter
the burner. The flames should ignite the gas. Turngas valve as needed for proper burner functioning.

A quick coupler is very convenient to attaching and detaching the burner from the propane hose.

CAUTION: Igniting the burner with a crumpled wad of newspaper may result in burning pieces of paper
floating out the furnace.
Once the burner is running properly lower the lid into position. If the burner did not ignite before the paper burned out allow the furnace to air out the gas fumes then repeat the procedure. If the flame extinguishes CLOSE THE GAS VALVE IMMEDIATELY. Let the furnace air out and then relight it.
If the burner will not stay lit the gas pressure at the regulator may be too high. Turn it down and retry theburner. On cold or windy days it may be difficult to ignite the burner reliably. In this situation you can soaka piece of charcoal in charcoal lighter fluid and ignite it in front of the burner. This burning charcoal should
keep the flame burning until the furnace is warmed up. Let the burner run at a lower flame setting for 2
minutes to heat the furnace before turning it up to full operating flame.
If the burner produces a pulsating, “woopf...woopf...woopf...” type of sound there may be too muchback-pressure in the furnace. Back-pressure is the pressure created from the burning gas as it expands andleaves the furnace as exhaust. Try sliding the burner backward away from the chamber. If that does not
solve the problem the gas pressure may be incorrect. The burner sound should be like a smooth sound of“rushing wind” or like a large plumber’s soldering torch.
Once the furnace is warmed up turn the burner up as needed and allow the metal in the crucible to begin
melting. At this point any other metal to be added to the crucible must be preheated by setting it on the furnace lid near the vent hole. Do not obscure the vent hole as this can cause excessive back pressure in thefurnace and blow out the burner’s flame.

Propane safety rules
Check all connections for leaks with leak detector or soapy water. If a leak is detected tighten the fittings.
Teflon tape designed for gas fittings should be applied to all threads. If the leak can not be corrected do not
use the system. Check burner for obstructions such as dirt, rust, metal splatter etc. Clear them away if present. Examine the propane hose for cracks or other damage. Replace the hose if necessary. For safety, replace the hose every two years.
Always use caution when igniting the burner. Keep all body parts as far away as possible and wear appropriate safety gear. Keep the propane tank as far from the furnace as possible. The propane tank should bedown wind of the furnace. This will blow any leaking propane away from the flame if a leak occurred. Always keep the propane tank in an upright position.
Never use a flame to check for gas leaks, keep children and pets safely away from the hot furnace or operating burner. Do not use the furnace without a regulator or with an improper regulator. Keep the propane
tank’s valve closed when not in use. And comply with all local, state, and federal regulations when operating this equipment.
Suppliers
Propane components
To properly use this burner the following propane components are required; An adjustable HIGH pressure
propane regulator, propane hose (10 feet is recommended) and a POL fitting which attaches the hose to thepropane tank. The following companies sell these items as a combo. Since links change I’ll only provide themain homepage address.
The Cajun Shoppe — Here is a source for high pressure adjustable propane regulators and propane hose.
They sell several combos of hose and regulator. However the company specializes in southern Louisiana
style cooking and cooking utensils. Their website is www.cajunshoppe.com

Tejas Smokers — Here is another company that sells propane regulators and hose combinations. Their specialty is barbecue grill apparatus.
Their website is http://www.tejassmokers.com/