Canoath
18th Jun 2015, 01:04 AM
I can't really remember exactly when I decided to have a go at blacksmithing but around this time in 2013 I started clearing out the shed to reorganise, insulate and line it. As part of setting up a woodwork and metalwork area I had already had in mind a forge would go in a corner, complete with anvil and post vice, a range of hammers and tongs. If you've ever seen the Blacksmithing episode of the BBC series Mastercrafts, that's what I wanted. Never going to happen but at least I could have elements of that traditional English setting like a bricked forge, massive anvil, coal or coke and all those tools, throw some brick stencils on the gyprock walls for authenticity. :rolleyes:
Here's a link to that episode, well worth a watch https://www.youtube.com/watch?v=5Kz_Aw7W97M
As reality set in I got inspiration from what people make do with. I've already talked about anvils as I've settled for one made from rail line and although I've got the bricks and a bit of bricking under my belt to confidently pull off a satisfactory brick forge, I can't commit to a permanent place for it. An LPG forge could be a goer but part of all this is just enjoying poking a fire. Speaking of fuel types, where do you get coal? I don't care anymore really, I just don't get how so much is dug up and shipped off yet you can't buy a bag readily. Same as coke which is becoming harder to source. There's really negligible domestic demand but anyway, I saw something about charcoal ages ago, watched a couple of docos and tried heating up scrap metal in the wood heater with charcoal. Worked well and I can make it myself but how will it go in a forge with blower. So far, really well though I've only test fired and haven't tried to reach welding temps. I've read charcoal burns quicker and may not burn as hot as the other two but I'm impressed so far.
There wasn't much online for charcoal forges specifically so I looked at different firepot designs for coke and coal users and the following's what I've come up with.
The measurements in white are incorrect. I got them off a video I saw ages ago, wrote the measurements down and copied them. The geometry didn't work so I came up with my own of 12" x 11" top and approx 3" x 2 and a bit inches for the bottom and used common angles copied with a sliding bevel. It was pretty rough cutting with the grinder and afterwards I clamped like sides together to grind them to match. I'm using old 5mm plate and once welded the pot is only 2" in depth. Not as deep as I thought it would end up.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_11_40_54_Pro_zpsckyfcfbn.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_11_40_54_Pro_zpsckyfcfbn.jpg.html)
Took a while to setup and tack. I'm using 0.9mm gasless mig which I'm not real good with. I much prefer stick and have never tried gmaw.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_13_31_05_Pro_zpsd7hny1uu.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_13_31_05_Pro_zpsd7hny1uu.jpg.html)
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_13_40_25_Pro_zpslqcn0fv2.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_13_40_25_Pro_zpslqcn0fv2.jpg.html)
I'm putting angle around it so it can drop into a table.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_14_11_47_Pro_zpstnmqkfj6.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_14_11_47_Pro_zpstnmqkfj6.jpg.html)
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_14_38_24_Pro_zpsktvzrjex.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_14_38_24_Pro_zpsktvzrjex.jpg.html)
There's bits of bar tacked to the bottom to not only act as a grate but may be rearranged at angles like fins to direct the air if need be. I do need to add another fin or add thinner sections on top at right angles because after going through half a bucket of charcoal this afternoon, too many smaller unburnt bits fell through the grate.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_20_37_34_Pro_zpscek1c3i3.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_20_37_34_Pro_zpscek1c3i3.jpg.html)
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_17_39_34_Pro_zpsk0o7fbiq.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_17_39_34_Pro_zpsk0o7fbiq.jpg.html)
For the test fire, I placed the pot on 100x4mm round pipe which rested on two rail offcuts, gapped to allow air to be forced through with a tiny hair dryer. Scrap is used to cover the gap. I didn't think it would be up to the task but it was more than adequate. Eventually I want bellows, despite the convenience of an electrically powered fan. A few coals were taken from the wood heater then charcoal on top. With the blower turned on you get sparks but negligible smoke. I placed the big pedestal fan as shown and it pushed sparks and fumes outside. Lots of circulation with two opposing doors open so no dramas re fumes in the shed.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_17_56_31_Pro_zpsthceewsi.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_17_56_31_Pro_zpsthceewsi.jpg.html)
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_17_57_19_Pro_zpsjkvbrkio.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_17_57_19_Pro_zpsjkvbrkio.jpg.html)
Despite the shallow pot it heated thin and thick pretty quickly without a huge mound of charcoal.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_17_51_38_Pro_zpseg5qshlh.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_17_51_38_Pro_zpseg5qshlh.jpg.html)
I really need to make tongs.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_18_01_34_Pro_zpsa1zmharj.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_18_01_34_Pro_zpsa1zmharj.jpg.html)
I'm estimating under 5 litres volume of loose charcoal was consumed in 30 mins and two cup fulls of smaller charcoal fell through the grate unburnt. No clinker either, just a bit of light ash.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_18_15_56_Pro_zpsoylwzn4y.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_18_15_56_Pro_zpsoylwzn4y.jpg.html)
Here's a link to that episode, well worth a watch https://www.youtube.com/watch?v=5Kz_Aw7W97M
As reality set in I got inspiration from what people make do with. I've already talked about anvils as I've settled for one made from rail line and although I've got the bricks and a bit of bricking under my belt to confidently pull off a satisfactory brick forge, I can't commit to a permanent place for it. An LPG forge could be a goer but part of all this is just enjoying poking a fire. Speaking of fuel types, where do you get coal? I don't care anymore really, I just don't get how so much is dug up and shipped off yet you can't buy a bag readily. Same as coke which is becoming harder to source. There's really negligible domestic demand but anyway, I saw something about charcoal ages ago, watched a couple of docos and tried heating up scrap metal in the wood heater with charcoal. Worked well and I can make it myself but how will it go in a forge with blower. So far, really well though I've only test fired and haven't tried to reach welding temps. I've read charcoal burns quicker and may not burn as hot as the other two but I'm impressed so far.
There wasn't much online for charcoal forges specifically so I looked at different firepot designs for coke and coal users and the following's what I've come up with.
The measurements in white are incorrect. I got them off a video I saw ages ago, wrote the measurements down and copied them. The geometry didn't work so I came up with my own of 12" x 11" top and approx 3" x 2 and a bit inches for the bottom and used common angles copied with a sliding bevel. It was pretty rough cutting with the grinder and afterwards I clamped like sides together to grind them to match. I'm using old 5mm plate and once welded the pot is only 2" in depth. Not as deep as I thought it would end up.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_11_40_54_Pro_zpsckyfcfbn.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_11_40_54_Pro_zpsckyfcfbn.jpg.html)
Took a while to setup and tack. I'm using 0.9mm gasless mig which I'm not real good with. I much prefer stick and have never tried gmaw.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_13_31_05_Pro_zpsd7hny1uu.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_13_31_05_Pro_zpsd7hny1uu.jpg.html)
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_13_40_25_Pro_zpslqcn0fv2.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_13_40_25_Pro_zpslqcn0fv2.jpg.html)
I'm putting angle around it so it can drop into a table.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_14_11_47_Pro_zpstnmqkfj6.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_14_11_47_Pro_zpstnmqkfj6.jpg.html)
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_14_38_24_Pro_zpsktvzrjex.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_14_38_24_Pro_zpsktvzrjex.jpg.html)
There's bits of bar tacked to the bottom to not only act as a grate but may be rearranged at angles like fins to direct the air if need be. I do need to add another fin or add thinner sections on top at right angles because after going through half a bucket of charcoal this afternoon, too many smaller unburnt bits fell through the grate.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_20_37_34_Pro_zpscek1c3i3.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_20_37_34_Pro_zpscek1c3i3.jpg.html)
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_17_39_34_Pro_zpsk0o7fbiq.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_17_39_34_Pro_zpsk0o7fbiq.jpg.html)
For the test fire, I placed the pot on 100x4mm round pipe which rested on two rail offcuts, gapped to allow air to be forced through with a tiny hair dryer. Scrap is used to cover the gap. I didn't think it would be up to the task but it was more than adequate. Eventually I want bellows, despite the convenience of an electrically powered fan. A few coals were taken from the wood heater then charcoal on top. With the blower turned on you get sparks but negligible smoke. I placed the big pedestal fan as shown and it pushed sparks and fumes outside. Lots of circulation with two opposing doors open so no dramas re fumes in the shed.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_17_56_31_Pro_zpsthceewsi.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_17_56_31_Pro_zpsthceewsi.jpg.html)
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_17_57_19_Pro_zpsjkvbrkio.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_17_57_19_Pro_zpsjkvbrkio.jpg.html)
Despite the shallow pot it heated thin and thick pretty quickly without a huge mound of charcoal.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_17_51_38_Pro_zpseg5qshlh.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_17_51_38_Pro_zpseg5qshlh.jpg.html)
I really need to make tongs.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_18_01_34_Pro_zpsa1zmharj.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_18_01_34_Pro_zpsa1zmharj.jpg.html)
I'm estimating under 5 litres volume of loose charcoal was consumed in 30 mins and two cup fulls of smaller charcoal fell through the grate unburnt. No clinker either, just a bit of light ash.
http://i1097.photobucket.com/albums/g354/povo56/Anvil/WP_20150617_18_15_56_Pro_zpsoylwzn4y.jpg (http://s1097.photobucket.com/user/povo56/media/Anvil/WP_20150617_18_15_56_Pro_zpsoylwzn4y.jpg.html)