This is a small forge I slapped together using elements from several designs I have seen on this website. I used a chimney flue and some firebrick I had lying around. I have never done anything like this before but I decided to give it a whirl. I had all the supplies lying around, but you should be able to go to your local hardware store and get them. This is a charcoal fired forge that should stand up to the high temperatures necessary to melt aluminum, and soften or even melt iron and steel.
1 section of round ceramic chimney flue (about 10-12 " in diameter)
Bucket of chimney cement (or something like it)
18"x8" section of steel sheet metal, fairly thin( you can bend into a tube)
A blow-drier (will not be damaged)
Circular saw with diamond glass/ceramic-cutting blade
6"x1"x1" block of wood with a 45* angle cut on one end
aviator sheers (or any kind of sheers that will cut the sheet metal)
When used properly this forge will be producing very high temperatures. Please use caution. I am not liable.
Step 1: Getting Everything Together
Using a circular saw with a diamond blade, cut an 8" section of the flue. This will be the body of the forge.
Arrange the bricks on the ground, or a sheet of plywood, so that you have a platform wide enough for the flue pipe to sit on, with a space between two of the bricks for the bellows pipe (a gap about 2") See Photo. there will be brick protruding for the outside, (I used half bricks) they can be cut off or rearranged, or left. your choice.
Take the sheet metal and bend it around a pipe or something round until you have an 18" long pipe about 2" in diameter. it needs to fit into the gap in the bricks so that the end is about in the center of the flue pipe on top of the bricks. Use self tapping screws to anchor so the pipe keeps its shape. Cut out half of pipe inside the forge so air can get inside. Dry fit everything to make sure it works.