Ready to get your hands dirty?
>Plaster of Paris...................Joan Ann's Fabric
>Sand....................................From the backyard
>Cardboard...........................Large Egg Carton
>Several large buckets
Make sure you lay everything out in easy to reach places. The "Plaster of Paris" starts to harden as soon as you stop stirring. So make sure you are ready to move on to the next step.
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Step 1: Preparation
A) Use the sieve to filter the sand and remove unwanted materials like sticks and rocks. Put filtered sand into a bucket.
B) Cut the ends off two trays and tape the cut end using masking tape. This will be for the base of the forge. Tape the trays to desired length.
C) Use the cardboard and masking tape to create the desired shape and size of inside the forge. Keep in mind you need to access the crucible inside and it must have an air vent at or near the base to put a fan for rapid airflow.
Step 2: Mixing and Coating
A) Measure an even ratio (1:1) of sand and plaster using a cup. Pour in a little water and mix thoroughly. The mixture should have the same texture as cement mix. Not too thick or it would set faster and not too watery or it will not hold it's shape well.
B) Pour mixture into the trays and smooth top to form the base. The base should be about 1" thick.
C) Cover the outside of the cardboard mold with a thin layer of the mixture. Let it set.
D) Repeat "C" until the walls of the forge are 3/4" to 1" thick. Let dry overnight.
Step 3: Ready to Use
The little forge is now done and ready to be used.
A) Soak the cardboard with lighter fluid.
B) Place coals at the bottom of the forge and also soak in liter fluid.
C) Be careful when lighting the coals. Place fans in proper place and burn out the cardboard
D) Enjoy melting those aluminum cans.
This can also make a nice little outdoor stove and mini oven. Just change the shape with a flat top to heat a frying pan on. Enjoy you new little Blacksmith/Chief's tool.