I believe that wax would just vaporize as the lead came in contact with it. It would be best done outside or with the Templo lead that is available. I would also pour it in from one end so the lead doesn't cover the wax over and cause it to explode. Maybe have vent holes in the bottom of the casting box to let any wax that just melts out.
Hi Dave:
If you are using a wax pattern, heat it up after the plaster has cured and pour out the wax before you pour in the molten lead, to reduce the flames when the wax boils and catches fire.
Also, if you add some fine sand to the plaster it will make it weaker and easier to remove.
One of the guys I work with built a furnace in his backyard and he told me that "greensand" is actually regular sand mixed with another mineral that is actually or very close to pulerized kitty liter.
You can also carve a pattern out of small cell styrofoam, then leave the styrofoam in the mold, and the molten lead with burn it to a thin film, or dig it out of the mold before you pour, if you wish..
Or you could just pour a simple little brick of lead close to the size you want, then file and drill it to the finished shape you need.
BTW, if you've ever dissected a modern car battery, you've seen that there is no usable lead in the plates, only a few ounces from the two external posts and the connections to the plates.
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