The hardest part of it that I can see is selecting a proper material. I would want to be sure before I started heating and pouring metal that it was going to be right, as Oldskool said there are many different types of aluminum for casting, using the wrong type would be bad. If you did your homework I don't see why it wouldn't work. Not sure that the cost of materials needed to build a mold and heat material would offset the cost of having one or two sets machined, but if you were goanna make a bunch of them it might get cheaper. The stress test is a real good idea too. BTW if your thinking about melting previously cast items known to be made of a specific alloy I would check to make sure re-casting is possible without changing the metal's properties.
NEMPD.... soon
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