Make a Small Blacksmith's Forge

Make a Small Blacksmith\
A small forge for Blacksmiths, not a forge for small blacksmiths.
A long-term goal of mine's been to have a forge small enough and well-mannered to keep in my suburban garden, so that means no bituminous coal. I considered a Gas forge but when that turned out to be impractical for the scale of work i want to do, i looked elsewhere. Plus, with a gas forge i'd probably have ended up blowing my legs off.
So, suburban (so no smoke) and i can't use gas.... the only alternative i could see was charcoal. Finding a lost middle-american civilisation in among my socks would be considerably easier than finding the kiind of charcoal i need in the amounts i need. -everyone wanted to sell me a few tons at least-
Eventually, i found something called "smokeless fuel" seemed to be pure carbon or something, so because it was only £1.75 for 10 kilos i decided to give it a try...
 
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Step 1Find something to make the forge in

Find something to make the forge in
I WANTED to use a wheel from a car to do this but i couldn't be bothered going all the way to a place to get it only to carry it home and eventually set it on fire, so i looked closer to home. I ended up using a 12 inch stainless steel cake tin. I never once thought i'd be making a forge in something that vould have been used to hold cakes but it worked really well.
The first thing we need to consider when building a forge is the ariflow. Too much and it gets far too hot. Not enough and it doesn't burn at all. To get the air into the forge, we need a hole through which we can out a pipe. Wheels come with ready-made holes. Cake tins do not. Ergo, i had to make one. "It's only thin steel, what can possibly go wrong?"
I spent something like 40 minutes getting a hole big enough to put the pipe through. SO: this step's instructions: Through Fair means or Foul, Make a hole big enough to fit the pipe through. Make sure the pipe doesn't go too far in or not far enough in. about 1.5 inches was right for me.
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158 comments
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Jul 24, 2011. 8:34 AMyoubaka1 says:
can you make a charcoal forge that uses belows instead of a hairdryer?and can you make it out of fire brick?
Nov 9, 2011. 3:30 PMshocker187 says:
Yes and yes. Bellows were the normal blower for thousands of years and still work fine .They can be simply built from wood ,leather and some thin metal sheet ,but as has been mentioned else where ,a blacksmiths hand crank blower is better .The problem I saw with that advice is that if you knew where to get (or had) a blacksmiths hand crank blower you would be unlikely to be asking how to build a forge ! A thing I had been considering was taking a scrap turbocharger from a wrecked car and adapting that to a hand crank.....a idea for you ? Makes you independent of power supply.

Fire bricks ,I had built a firebrick forge like a brick built BBQ ,just using the fire bricks at the business end .Just remember to build your tuyere/air pipe into the structure as is a sod to put in after !
Jan 22, 2012. 9:56 AMUuvini says:
Another option is a bathroom exhaust fan, You can usually pick one up for $20-$30.
Jan 5, 2012. 5:56 PMZipmiestermag#56 says:
What about a length of steel H-beam? Would that make a good anvil?
Oct 2, 2011. 9:12 PMepeisel says:
Once again I (as a novice and total noob) will have to guess as to what the "master" is talking about... A total mystery and complete failure of explanation here...
Oct 31, 2011. 4:31 PMDustan44 says:
Which part is confusing you epeisel?
Oct 2, 2011. 9:16 PMepeisel says:
You realize that you have said exactly 3 words concerning this "blower?" I don't suppose you could actually provide some insight into this mechanism, could you? I mean, gods forbid you should actually educate anyone...
Oct 2, 2011. 9:14 PMepeisel says:
The complete inconsistency of the various frames lead me to believe that this person should never be entrusted with the education and teaching of another human being... In anything...
Sep 4, 2011. 4:43 PMthe walking stick says:
When I wanted a cheap anvil I went with a 12 in section of old railroad. works great. If you live in AZ there are some blacksmiths and industrial places that will sell you sections. mine was about $20. Other then that, I don't have any idea where you'd get old RR track.
Jul 24, 2011. 8:29 AMyoubaka1 says:
hey can you make a charcoal/coal forge? me and my dad have been looking around for anvils and hammers and all the stuff required for forging but we havent found a good design for a forge
Sep 19, 2009. 11:59 AMsharlston says:
could you melt sand with this?
Oct 25, 2009. 6:23 PMkmccarthy666 says:
I doubt it since sand melts at about 8000 degrees and the only thing I can think of that burns at  that temp is hydrogen.. why do you wanna make your own glass bong or something?
Jul 9, 2011. 10:48 PMsnowluck2345 says:
and acetylene with oxygen...
Nov 15, 2009. 11:17 AMsharlston says:
i would like to make a little blob of glass
Mar 13, 2010. 6:53 AMjosh1324 says:
...      Why?
Mar 13, 2010. 6:56 AMsharlston says:
just corious into makingo ne
Mar 13, 2010. 10:44 AMjosh1324 says:
cool
Mar 8, 2010. 12:10 AMx z i t says:
YOU NEED MANY CHEMICALS TO MAKE GLASS, NOT JUST SAND AND GLASS AND BAKING SODA. ALSO, THE FUMES THAT COME OUT OF THEM IS TOXIC. I SUGGEST METAL
Jul 9, 2011. 9:52 PMacoleman3 says:
sorry but glass is only sand and soda with some lime added.

The most familiar type of glass, used for centuries in windows and drinking vessels, is soda-lime glass, made of about 75% silica (SiO2) plus Na2O, CaO, and several minor additives. -wikipedia.
Feb 5, 2011. 4:44 PMsnowluck2345 says:
First of all: Don't write in all caps, its annoying
Second of all: Sand melts at around 3000-3500 degrees fahrenhite. You could probably melt pyrex in this or you could melt sand when mixed with borax.
Jul 9, 2011. 9:54 PMacoleman3 says:
with the addition of soda and lime, it drops the melting temperature of the sand closer to 2k*. pyrex is the one tht melts around 3k.
Jul 9, 2011. 10:15 PMacoleman3 says:
to let you know....the best fuel for this is mesquite charcoal lump. its pretty easy to find since its the type used in the food service. i got 40lb bags of it for about $13 from a place called cash and carry. they cater to restaurants, but its open to the public. i use this when i was running my forge a lot. i was using the tim lively style bladesmithing forge and was only burning about 2 lbs/hr.

if you drill 3/16 in holes about every inch, you can run the pipe clear through so you end up with a tuyere and get a more consistent heat clear across the coal bed.
Mar 7, 2007. 10:55 PMjemtallon says:
My grandpa used to make anvils from old railroad rails. I'm not sure how/where he got the rails cut down to size but I have one of his old anvils still and it works fine. If you can find a way to buy some old track off of someone and get it cut, it might be a cheap anvil for you too. The thing I like about it is that it's light enough to be portable but it's still pretty heavy duty. If you'd like a picture, let me know.
Mar 14, 2008. 5:04 AMkcfreeloader says:
I've seen lot of people use a foot long piece of hard steel sticking up a few inches out of a five gallon bucket with concrete poured around it. You could do the same thing with the sledge hammer head. Just leave a few inches sticking above the concrete.
Jul 9, 2011. 10:09 PMacoleman3 says:
make another one and reinforce it with a rebar cage. it'll reduce the interior shock stress and wont crumble as easily. this is what tim lively uses and hes had it for years now.
Mar 24, 2008. 4:13 PMthoraxe says:
I heard u can get arrested if u get caught with railroad track without written permission from the station or company.
Sep 5, 2011. 7:07 AMElmoRoyD says:
I think it depends on the country, here in Mexico is illegal to have railroads tracks, without a permission. thats becouse The government own the railroad tracks, and a lot of people steals it.

It may also depend on the size of it.
Mar 25, 2008. 9:59 AMjemtallon says:
That may be - I'm not sure. I got mine from my grandpa who supposedly bought it from the railroad many years ago (I think in the 60s). I imagine a quick call to them would solve the issue if you're interested in making one. You'd want to contact them anyway if you wanted to buy one :)
Apr 1, 2008. 1:16 AMn0ukf says:
I went to the local railroad maintenance shop and asked about spikes in their scrap bin. They said take what I want. I got some short pices of rail (even some 1/8" to 1" slices) and a couple pieces of rail 3' long... man that's heavy to move without help. If you see numbers on the side, that's likely the weight per yard, so if you see 139 on the side, it's a 139 pound per yard rail. No telling what you might find if you ask for their junk. And there was no written permission. It's a hunk of steel, not some illegal substance.
Sep 4, 2011. 6:43 PMfacilitator476 says:
I think that the problem is that parts for the railroad are either state or government property. It's some level of illegal to take them off the track, for obvious reasons. I just wish that the scrap yard down the street would take the spikes they leave on the side of the tracks. They have to way a couple pounds apiece
Apr 1, 2008. 8:37 AMthoraxe says:
Well, ask the guy from PurgatoryIronWorks on youtube. he's the one who told me.
Sep 3, 2011. 5:18 PMJuCo says:
now, this is just a guess... but it could possibly be a law that's on the books to deter people from taking lengths of rail from active lines. (for use or to sell for scrap)

this way the police just have to prove you're in possession rather than having to try to prove that you took that length of rail from that line.
Sep 4, 2011. 4:49 PMthe walking stick says:
I'm sure thats what it is. they don't want people taking lengths out of an active line. There's that scene in October sky where they take a section out to sell for money and the train comes along behind them. So I can see the logic there. but our country does have a large amount of not in use lines, so scrap can be found. lots of scrap yards I've visited have had sections as well
Sep 4, 2011. 8:37 PMJuCo says:
oh, absolutely... now that you reminded me of "october sky", that scene is a perfect example of an area that is littered with now-dead train lines. the mine shuts down, the line goes dead, and half the time (especially back when that movie was set) they leave the tracks.

my mom was showing me where she used to work once and right over the fence from the parking lot was about 30 yards of track and 2 train cars. just sitting there. no other track anywhere in the area. it made me wish i had the money to buy those cars. they were 2 passenger cars. i don't know too much about the different train styles, but the accents and trim suggested that they were probably built somewhere between the 60's and the 80's.
Sep 6, 2011. 11:48 AMthe walking stick says:
well that'd be a great place to get track from, granted I got no idea how you're going to chop off a small section. feel like it'd kill a reciprocating saw....
Sep 6, 2011. 2:42 PMJuCo says:
maybe chew on it a while? :o)
Sep 7, 2011. 9:36 PMthe walking stick says:
oh and i've been using it length wise, rather then vertical. its fairly flat on top, great for knifemaking
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