Byron Campbell wrote:Hi Joe, Welcome to Permies.
Casting makes sense, especially if you're planning on building more than one core. But the time in making forms, and dealing with a homebrew mix of refractory to get it just right, and procuring or building a vibrating-platform to settle the mix into the forms, is for most folks a great deal more time consuming than say, just picking up a couple of boxes of insulating fire brick (i.e. IFB, ~2300° F) and building an all brick batch box with heat riser.
An example of Peter van den Berg's "batchbox" in brick is attached below, a 6-inch system-size constructed from fire brick. I built mine with standard (dense) fire brick for the firebox, and IFB for the heat riser. Makes for a very rugged trouble free stove that takes a beating and keeps on going for years and years.
But it depends on what you're after, as to what you build, and what you're intending on heating -- shop, out-building, living quarters, etc.