Step 1: Materials
!!Important lots of heat and fumes given off so out side is a must for this type of forge, when the worked mettle is taken out it will be red-white hot, you will feel the heat from a distance so don’t let it get any where near your or any ones skin or body or it will hurt, a lot!!
The materials needed for constructing a non-permanent forge depends on the size and shape, this forge was made for the job of forging the blade of my sword, so I will list the materials as if u was replicating this exactly (or kind of).
•Building bricks with 2-3 holes, x8
•Solid building bricks (sand stone bricks not as good due to the heat) aprox x40
•Roofing tiles x5
•Breeze block x1
•Slabs x2-3 (depending on size of slabs)
•Hair dryer x2 (similar powers)
•Soft clay about 1kg
Sword (if making)
•Steel to work, suggest part of a small car leaf spring because of the high carbon factor and easy to work size another easy option is a car coil spring cut up. But for testing any steel can be used, a good thing to play with is reinforcing rods as you can make tongs for later use with the forge
•Length of reinforcing rod or other steel rod, 1.5-2 cm diameter and about 23 cm long.
•Steel plate about 4cm x8cm for hand guard, can use a section of leaf spring as I did.
•Wood for handle, 26cm x20cm and 1.5cm in thickness, suggest a hard wood because it makes turning a smooth finish easier.
•Bolt aprox 2.5-4cm brass or steel depending on preference.
•Washer, fancy as it will be on the hilt or but plane is fine.
•Making the forge
•Working the forge
oBucket of water incase something happens (note tern off power to the hear dryers first, sounds silly but funny things happen when you panic).
oWater but for quenching, if you need to make hard brittle items.
oHeat proof gloves that reach up the arm.
oTongs, I found mole grips very useful but longer reach tongs may be found safer for retrieving smaller items from the forge.
oA solid lump of flat cast steel or iron. I used the back part pf a vice sat on a wall, this is far from ideal (just look at picture..).
oSelection of hammers with different heads and weights, tack up to club.
•Bench vice, on a bench this time.
•Lathe for turning handle, not a must but quicker than trying to plan it.
•Angel grinder for first sharpening and fine tuning.
•Bench water-stone, not a must but gives a better edge.
•Drill with sander attachment and a buffer attachment.
•Tap and die set.