Building a forge

[Thumper68]

I know we have a few Blacksmiths on here and I hope they join in here and give me a few pointers.

I have done a lot of research on this and thought it was time to get off my **** and get going.

I chose to re purpose my old welding table for the base.

Of course this is a teaser, the video of the build will be coming out soon.

 

[countryroad82]

Cool!

 

[akiwinut]

Will be following along on this one, what fuel will you be using?

 

[dougf]

I like it. What are you using as a blower? I'll be making a gas forge soon.

 

[Thumper68]

Will be following along on this one, what fuel will you be using?

Coal, I know most seem to prefer bituminous but getting that here is almost impossible so anthracite it is.

I like it. What are you using as a blower? I'll be making a gas forge soon.

A cheap bathroom fan unit with a speed control, if I can't get the control to work I will install a damper/bypass to control flow. Since I will be using anthracite coal as fuel I will need a constant volume of air to keep the fire going, hopefully the speed control works so I can add more air as needed.

I have plans for a gas forge as well, but wanted to go old school first and learn fire and heat control.

Tomorrow I have a video coming out on building a propane burner that could be used on a gas forge.

 

[landrover bodger]

for a blower I use a cheap hair dryer not the best thing but it works. it will get ordinary house coal hot so it will melt coil springs

 

[Thumper68]

for a blower I use a cheap hair dryer not the best thing but it works. it will get ordinary house coal hot so it will melt coil springs

That was one of the options I looked at, but I had the bathroom fan, so it was free.

 

[landrover bodger]

free is always best

 

[Farrier]

I've long since sold my coal forge(s). For me, gas is easy to use and super clean. Keep the pics rolling.

 

[MichaelBikel]

Following this with interest! Just started re-profiling a knife and i've wanted to forge my own axe/knives for a long time now. Maybe this will give me a nudge in the right direction.

 

[Thumper68]

I will be back on it later this week so stay tuned, video of the build coming in a few weeks.

Originally I had thought to build a quick brake drum forge, then I started doing some research and discovered that a brake drum is really the wrong size and shape for a forge, in order to get the right heat profile you need a longer narrow fire.

I searched a lot until I found several designs, including some commercial cast fire pots that had dimensions. They were all a bit different of course but 6x9 at the bottom and 9x13 at the top seemed to be the median size with a depth of 5 to 6 inches.

It became easy then since I have a few tons of 3/8ths x 6 inch flat stock.

The only materials I have had to buy so far is some 1 1/2 x 1/4" flat for the upper rim of the fire pot, the pot is just held into the table by gravity, which should not be a problem since I would guess its weight at around 60 pounds.

I have had a lot of fun on this so far, this is the only really heavy welding project I have done in some time. The beads might be short but the multiple passes with the weldment radiating the heat gets my blood going.

 

[Seppala]

Looks really good! Are you planning to use a side draft hood?

 

[Thumper68]

Looks really good! Are you planning to use a side draft hood?

I have not decided yet, I am also building a foundry furnace, and the thought of using one hood for both is appealing.

 

[Seppala]

Thumper68
It might be a false economy to use one hood for two purposes. The forge that you've built so far is perfect for a fabricated side draft hood. ABANA may still offer plans.

 

[Thumper68]

Thumper68
It might be a false economy to use one hood for two purposes. The forge that you've built so far is perfect for a fabricated side draft hood. ABANA may still offer plans.

After my last post I was thinking about it and I think you are right, a side draft will be perfect on it.

I was thinking of doing a side draft that outlets into the larger hood then out, my question is would this draft properly?

One nice thing is that I can try it and if it does not work then just pipe it out on its own.

If I want to use the foundry furnace inside it will require a hood so I need to build the hood no matter what.

 

[catalytic]

I have built a coal forge before. Here are some thoughts/tips:
1. You need more airflow than you think. The first two I built were starved for air -- no fun.
2. Why no insulation around your steel pan? Kaowool and firebrick can be had pretty cheap.
3. Have you considered adding some bent steel to make your rectangular-bottomed box more round-cornered? Corners == very uneven heat. Or, maybe you don't care since you plan to mostly just use the hottest part in the middle of the coals over the blower hole?
4. Blower holes clog up. It's worth thinking about how you're going to unclog them while everything is hot. At least put a T with a big handle to release the hole on it where you join the vertical and horizontal pipes such that you can open it up and let the junk fall out (a bit like the galvanized part with 4 holes that you can twist open at the bottom of a Weber barbeque)

Cool project.

 

[Seppala]

Thumper68
Sorry, I can't offer any suggestions based on experience on piping to draft from one outlet to another. The steel fabricated side draft that I worked at on occasion had a 10 inch round pipe outlet straight up through the roof. It "sucked" ok but probably would have drawn better with a 12 inch diameter pipe.

 

[Thumper68]

I have built a coal forge before. Here are some thoughts/tips:
1. You need more airflow than you think. The first two I built were starved for air -- no fun.
2. Why no insulation around your steel pan? Kaowool and firebrick can be had pretty cheap.
3. Have you considered adding some bent steel to make your rectangular-bottomed box more round-cornered? Corners == very uneven heat. Or, maybe you don't care since you plan to mostly just use the hottest part in the middle of the coals over the blower hole?
4. Blower holes clog up. It's worth thinking about how you're going to unclog them while everything is hot. At least put a T with a big handle to release the hole on it where you join the vertical and horizontal pipes such that you can open it up and let the junk fall out (a bit like the galvanized part with 4 holes that you can twist open at the bottom of a Weber barbeque)

Cool project.

The fan I have should put out more then enough air, as long as I can keep the clinkers from building up. If it doesn't then I will have to add a larger one.
I never thought about insulation or seen it done that way, something to think about. Why would it be needed?
I am working on the design for the clinker breaker right now, it is one of the last things that I need to figure out

Thumper68
Sorry, I can't offer any suggestions based on experience on piping to draft from one outlet to another. The steel fabricated side draft that I worked at on occasion had a 10 inch round pipe outlet straight up through the roof. It "sucked" ok but probably would have drawn better with a 12 inch diameter pipe.

10 inch seems to be what everyone is using.

 

[Ironhorse74]

You can buy bags coal from these guys. http://www.buycoalonline.com/

 

[Thumper68]

You can buy bags coal from these guys. http://www.buycoalonline.com/

Thanks for the link but I can get coal at tractor supply a lot cheaper.

 

[HMCFab9]

Nice forge build so far! Keep us posted on your progress.
I'm building a forge also.....& hoping to get it hot pretty soon!

 

[Thumper68]

Well today is the day, I finished it up (mostly, still need to work out how to get rid of the smoke) But I am headed out to the shop to start a fire.

Of course all I have to work with is green coal and my understanding is that it is hard to get the green coal burning, watched a bunch of video's and read a few threads last night, so we shall see how it goes.

 

[Thumper68]

WoooHooo!!

We have FIRE!!!

To be honest I was a bit concerned after reading about all the issues people have had getting green anthracite coal to fire off, and I am sure that I will have issues as well.

I started with a news paper and wood, got that going and started adding coal a bit at a time with low air flow, once the wood was burning well I increased the air flow and just watched and waited, soon enough I could see glowing coals in the pot, I played with the air flow a bit and after 20 minutes or so I had a good fire going.

I heated a few pieces of steel and pounded on them a bit, not trying to make anything but just to do it.

Now comes the fun part taking a chunk of steel and making something, first off I need a rake and poker. Probably a good thing that I have several lengths of 3/8ths rod to play with.

 

[oldironfarmer]

I use sawdust to pick up oil on my shop floor. Oil soaked sawdust makes a great fire starter in the forge, clean out your fire of clinkers, throw a handful of sawdust in, light it with a match and cover it back up, turn the air on low and you'll have a quick fire. I can get a 3/8" round red hot in 3 minutes from striking the match. Faster than getting the cutting torch lit and adjusted.

You'll have plenty of coke from now on, just be sure to keep adding green coal around the fire to coke it while you're working.

And keep the air off when you're not heating or you'll burn up a lot of coal. Hot coke will stay hot with no air for a long as you can work hot metal. Don't know if you're using a speed control, but small fans will stall nicely, just shut off the air flow and electricity use will go down too. Most speed controls dump electricity through a resistor so they are not efficient.

Happy forging! Get used to it and you'll be using it instead of acetylene for lots of things.

If you want to use two flues into one chimney you need to plug the unused one, that's all. I use a 12-inch chimney.

 

[Thumper68]

I use sawdust to pick up oil on my shop floor. Oil soaked sawdust makes a great fire starter in the forge, clean out your fire of clinkers, throw a handful of sawdust in, light it with a match and cover it back up, turn the air on low and you'll have a quick fire. I can get a 3/8" round red hot in 3 minutes from striking the match. Faster than getting the cutting torch lit and adjusted.

You'll have plenty of coke from now on, just be sure to keep adding green coal around the fire to coke it while you're working.

And keep the air off when you're not heating or you'll burn up a lot of coal. Hot coke will stay hot with no air for a long as you can work hot metal. Don't know if you're using a speed control, but small fans will stall nicely, just shut off the air flow and electricity use will go down too. Most speed controls dump electricity through a resistor so they are not efficient.

Happy forging! Get used to it and you'll be using it instead of acetylene for lots of things.

If you want to use two flues into one chimney you need to plug the unused one, that's all. I use a 12-inch chimney.

Thanks for the tips, I use sawdust as well to clean up spills, I will have to start keeping the oil soaked stuff.

I did read that when you are done with the forge you should pack it with green coal so you have plenty of coke for the next firing and that is what I did today.

 

[Slycox]

I don't know **** about forges but to light our coal fired boilers at work we use road flairs. Don't know if it would be to much for your application.

 

[Thumper68]

I don't know **** about forges but to light our coal fired boilers at work we use road flairs. Don't know if it would be to much for your application.

That might be a bit of over kill

So far I am 2 for 2 on ignition.

It has evidently been a long time since I have swung a hammer all day, or even 30 minutes straight my forearm seems a bit tired.

So far I have made one end of a rake and one end of a poker, I did the rake part of the rake, drawing out and bending the rake and doing a scroll and hook for the poker out of 3/8ths round bar.

Hoping to get some more time tonight to do a bit more with those and maybe see if I can make a pair of crude tongs.

After a bunch of reading I think I have decided to go with a powered vent hood at least for now.

 

[Slycox]

That might be a bit of over kill

So far I am 2 for 2 on ignition.

Ha I wasn't sure, take a good half to full dozen flairs to get our beds burning.

 

[wyo george]

I may have to give it a go at building and running a forge, it's something I've always wanted to do and since I have an almost endless supply of free Wyoming sub-bituminous coal I figure why not. I'll be watching and studying, it'll be a good winter project I think.

G

 

[Thumper68]

I may have to give it a go at building and running a forge, it's something I've always wanted to do and since I have an almost endless supply of free Wyoming sub-bituminous coal I figure why not. I'll be watching and studying, it'll be a good winter project I think.

G

Go for it!!

No forge work today, there was an auction this morning and I picked up a few things and I need to get the spot where the forge is going cleaned out and the hood built.

As much as I want to hammer on stuff all day I know that if I take the time now to get it all set up properly I will be much happier.

 

[Thumper68]

One video is up and ready for viewing.

 

[great white tj]

Nice build on your forge !!

 

[Thumper68]

Nice build on your forge !!

Thanks, I have only had time to fire it up twice so far, it does get hot though.

 

[landrover bodger]

Nice forge I wish I had seen that before l built mine

 

[Thumper68]

Nice forge I wish I had seen that before l built mine

I would love to see more forges. post up some pics.

Honestly I have no idea how the one I built is going to work in the long run, I tried to pick the best ideas from all the forges I looked at and build them into mine. But since I have no idea what I'm doing it could turn out to be a complete failure or the best forge ever

 

[landrover bodger]

a few of mine while I was building it . can you tell me the what that square you used for marking out is called . it looks very useful

 

[Thumper68]

a few of mine while I was building it . can you tell me the what that square you used for marking out is called . it looks very useful

The green one?

That is a quick square or speed square designed for carpenters.

https://www.amazon.co.uk/Swanson-Tool-Speed-Square-S0101/dp/B00002255O/ref=sr_1_1?ie=UTF8&qid=1475264855&sr=8-1&keywords=speed+square

That same square on us amazon is only $10, ****.

 

[Thumper68]

a few of mine while I was building it . can you tell me the what that square you used for marking out is called . it looks very useful

I like it, good size to move around, while I can move mine it is heavy and awkward.

 

[landrover bodger]

The green one?

That is a quick square or speed square designed for carpenters.

https://www.amazon.co.uk/Swanson-Tool-Speed-Square-S0101/dp/B00002255O/ref=sr_1_1?ie=UTF8&qid=1475264855&sr=8-1&keywords=speed+square

That same square on us amazon is only $10, ****.

that's the one thanks

 

[jumbojak]

If you're burning the Kimmel anthracite from Tractor Supply don't worry too much about the coal coking. In my experience it doesn't. Then again you might come across a bag of coking anthracite from them. I found the Kimmel to be of erratic quality. Some bags would burn very cleanly while others would quickly load up the firepot with clinker.

Also, the bigger and straighter you can make the chimney for your hood the better. Two pieces of six inch chimney can be zipped together to give a good diameter when nothing else can be found. I'm told that a 55 gallon drum will **** the fleas off a dog if it gets too close. Best of luck and happy hammering.