There was a very comprehensive article in the Shed mag a while back. I've done a little of it, but nothing complicated - and nothing critical on shrinkage as it was all needing to be machined after.
It was pretty much all as Maca suggested, two sand boxes with 'green' sand just damp enough to stick and two split forms.
The Shed mag article was good in that it discussed lost wax casting, which if done right can get better and more accurately cast results. I'd look into that and go from there maybe? And I won't mention that the last thing I cast in sand was a castle a few weeks ago haha.
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