Ye Olde Forge

[Screwdriver]

I decided to make up an angle frame as a base.

Then weld some bolts with adjuster nuts, pointing up as shown.

This was a nightmare of blowing holes and twisted angles. Not so much Tig welding as Tig casting.

They are "on" for sure but it took ages and I found it incredibly difficult to manoeuvre that drum into a position I could get the torch into.

Two more to do at the back. Then it should drop onto the frame bolts, I can adjust the height/level and crucially, still easily remove the forge or fit it onto another stand. It also means the entire drum is stainless and only turns into mild steel at the base. It will be held on by gravity for now but if it needs nailing down that should be easy to fettle.

 

[Screwdriver]

It might even work!

I am now torn between making a little sliding shelf for the floor/bricks or just stuffing it full of ceramic wool and letting them sit on that.

The frame sticks out at the front so that I can have a shelf or tong support in front of the door.

 

[Parm]

Watch out with the ceramic wool, it’s highly carcinogenic. Same health implications as asbestos

 

[gaz1]

line it with both firebrick and wool

https://www.ebay.co.uk/itm/THERMAL-...hash=item33bfe129d7:m:maoWCc7I_1z5qikLWgbibaQ

the ceramic is the insulator whilst the bricks take the brunt of the heat

This product is generally safe and is classified as a low risk to long term Human Health, it is also officially classified as a non carcinogenic product, but because the General public are not familiar with the product, i feel there is a responsibility to offer guidance towards a completely safe handling of it and also to give an explanation of any associated risks no matter how small.

 

[Screwdriver]

Watch out with the ceramic wool, it’s highly carcinogenic. Same health implications as asbestos

Yes thanks, I have read up on it. I wear full mask, gloves, respirator etc., I'll do it outside too.

@gaz1, I have a design in mind. Firebrick for the base, inside a double wrap of ceramic wool. That will will get several coats of a home made "slip" based on refractory mixed with sodium silicate. The door seal will get fire rope stuffed into the gap.

All that welding has distorted the frame and fit somewhat. I will need to adjust it with a precision hammer.

 

[captain-destructo]

Yes thanks, I have read up on it. I wear full mask, gloves, respirator etc., I'll do it outside too.

@gaz1, I have a design in mind. Firebrick for the base, inside a double wrap of ceramic wool. That will will get several coats of a home made "slip" based on refractory mixed with sodium silicate. The door seal will get fire rope stuffed into the gap.

All that welding has distorted the frame and fit somewhat. I will need to adjust it with a precision hammer.

measured to perfection ............ hammered to fit

 

[Chillitt]

measured to perfection ............ hammered to fit

If you want to be a blacksmith, hit the thing...

 

[Screwdriver]

Almost forgot, I need a hole and a mount for my burner.

Thought I'd keep it stainless as much as possible so reused one of the old parts.

Welding stainless is pretty easy.

So there's no excuse for doing it badly. Well, I haven't thought of one yet.

It moved a lot more than I expected, in fact the whole drum shifts substantially whenever it welds. Looking at the top picture it sort of makes sense I suppose. Heat has contracted the slope and tipped the mounting forwards. It is tough stuff. You can pound on this thing for ages with a sledge hammer and it wont shift...

Anyway, so long as the forge gets hot it will work no matter what it looks like and I am enjoying the build, learning stuff as I go.

 

[Parm]

If you want to be a blacksmith, hit the thing...

Both those comments have me chuckling away here

 

[Screwdriver]

I know what you're asking yourselves. Where's the catch?

There it is...

 

[Screwdriver]

So I waited for the heatwave to subside before getting dressed up like Darth Vader.

I cut it slightly larger in diameter, slightly larger than the required aperture and a bit too long...

It all went very well. Better than I had been expecting to be honest.

The door shuts firmly against the overhang forming a good seal even before I fit the fire rope seal for the inner lip. So I thought I'd push my luck and put the bricks in.

I'll be damned, they fit perfectly. I had been expecting to have to make a frame or some additional support but it feels pretty solid and they line up beautifully. There is room for one more layer which should tuck into the gap between the top of the brick and the side wall.

I think I'll take it out again before I tack up the "ports". I don't think they need to be fully welded out. Once that's done, I will give the inner ceramic wool a wash over with refractory cement.

 

[Screwdriver]

I don't know if anyone is watching this but anyway, today I mixed up some secret sauce to rigidise the ceramic wool.

Tried a few recipies, secret sauce being a mix of refractory cement and something else, something else on its own and something else mixed down with dihydrogen monoxide.

They have all set rock hard in the sun so I guess I can just use whatever goes on the easiest. I am also experimenting with using it to glue some of the longer spans in place in case of sag.

My welding has improved tremendously. Never mind all the big blobs where I have clearly blown holes everywhere else, there's a solid 4-5mm of "perfect" bead right there! <proud>

The whole time the thing wanted to bend like a regulation EU banana so I stuck a bolt in to try and stop it.

It seemed to work and the construction is pretty much done. I just need to machine up a collar clamp for the burner to fix to, glue in the ceramics, rigidise it and we're done.

While it's all apart I might as well hit it with a wire wheel and see if I can tidy it up a bit, lose the paint etc. It's just too damned hot to be doing anything tbh so that might have to wait until the sun cools off a bit.

 

[Screwdriver]

Out with the old.

In with the new.

 

[Chillitt]

Have you got a bit of tin or a paving slab to go under it?

 

[Screwdriver]

Have you got a bit of tin or a paving slab to go under it?

The plan is to have it sitting directly on those concrete slabs though in theory, the base shouldn't get too hot. The plywood is just there temporarily while I use the area for general purpose work.

I have fired it up and there is a snagging list.

The doors need blocking up with moveable fire brick so I need to fit a shelf at the front and make up a bung for the rear.

The burner works well in free space, less well in the new forge. Needs either decent setting up or a new design.

I might want it a teensy bit higher and maybe even on its own dedicated stand (hence the unfinished "workbench). It really ought to go in the fireproof section (where it is) meaning I need to raise the height of the workbench.

I think the anvil is also a bit on the low side even for me, I have raised it a bit but I want it higher than the optimum "knuckle height" the Internet would have you believe.

 

[Windy Miller]

Re your anvil, why did you put it on the stand for the swage block? Normally that stand is only used for an anvil when you work in pairs with a striker (or 2).

The anvil normally sits on a higher stand for general smithing work.

 

[Screwdriver]

Re your anvil, why did you put it on the stand for the swage block? Normally that stand is only used for an anvil when you work in pairs with a striker (or 2).

The anvil normally sits on a higher stand for general smithing work.

Because it came with it and (incredibly) is the original stand that this particular model of anvil is supplied with. It is quite common for people to mistake anvil stands for swage block stands but they are quite different. A swage block stand will generally be square (not oblong) and will have a slot for standing the block on its edge.

Becuase I have the stand, I need to find somewhere to store it and underneath the anvil is as good a spot as any

Ultimately I will be building a solid wooden stand not dissimilar to the swage block stand but I need to spend some time hammering stuff out to establish the height I am most comfortable with (hence the current Tower of Babel).

 

[Parm]

What are you planning to make? Have any plans or ideas

 

[Screwdriver]

What are you planning to make? Have any plans or ideas

Yeah, something out of rebar! LOL

 

[Parm]

Yeah, something out of rebar! LOL

Re bar cold chisels are quite good, made a few myself