I do some green sand metal casting. You might want to check out this yahoo groups web site. http://groups.yahoo.com/group/castinghobby/ Also you should really check out the David Gingery books on back yard metal casting. The first two books in the series show you how to build a furnace out of a 5 gallon metal pail, build patterns, brew up a batch of green sand, etc. As someone else mentioned there are some really good videos on youtube demonstrating the process. Search under Gingery and look for a series produced by tubalcain (sp?).
Tubalcain's username is MrPete222, the one I suggested. I think I've watched every metalworking episode he has out, and several of the other steam engine videos he has as well. His videos have been a great resource for me in my machinist class, and I make sure and check for new ones every few days.
I'm going to have to check out those Gingery books though, those sound cool. Thanks for the tip!