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[EmperorCoolidge]

Just checking if I have the details right and this plan will work.

I want to cast a giant wall out of obsidian, multiple z-levels tall. As I understand the mechanics, I will need to build a magma-safe cast, fill it with one of water or magma, then fill it with the other and repeat one z-level at a time yes? And starting from the lowest z-level of the wall. Will that work? Is there a more efficient way? Additionally, does the cast need to be a z-level higher than the section being filled to prevent spillover or will same height work as long as I keep an eye on the flow?

[Bumber]

The cast doesn't need to be magma safe, since magma has to flow through stuff to melt it. I'd build a temporary structure above where you want the highest z-level to go, with a (magma-safe) drawbridge (with magma-safe mechanisms) that holds magma, and another drawbridge above it that holds water. (You need walls around the drawbridge to keep the fluids in, obviously. These don't need to be magma-safe.) The bridges hold a limited amount of fluid so there's less risk of overfilling. You drop the magma first and let it fall down to the cast, followed by the (less dangerous) water. If you're worried about the water spilling (and spreading mud) then you should build the cast a level higher, otherwise you can let it spread out and evaporate. You can build the whole cast ahead of time, since you only need pump access to the drawbridges.

Just don't accidentally drop the water first, or it will obsidianize your drawbridges, which is a pain to fix.

[EmperorCoolidge]

Thanks! That will speed things up considerably, not to mention allowing the scaffold to protect the fort better in the mean time.