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Thread: Coal forge

  1. #76
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    Re: Coal forge

    There are plenty of ways to build a coal forge that don't require welding. If you browse the forum you'll find a number of brake drum/ brake rotor forges. Some screw together pipe parts and a few bolts to secure them to the rotor and you can be in business just to name one method. I've also seen some done using sheet metal and screws or rivets with an old sink lined with clay as the firepot.


    As far as a version of my forge, it's a copy of a forge very similar to one that Centaur Forge or Pieh Tool sells. Both have a variety of different models to choose from.

    http://www.centaurforge.com/Coal-Cok...partments/160/

    http://www.piehtoolco.com/contents/en-us/d1189.html
    .



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  2. #77
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    Re: Coal forge

    Was checking out the blower prices on those 2 sites... they get right pricey. I had a variable speed fan in the barn when I shut it down...might have to look at downsizing the fan size (18" is kind of big) and fitting it into some kind of shroud.
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  3. #78
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    Re: Coal forge

    Quote Originally Posted by whtbaron View Post
    Was checking out the blower prices on those 2 sites... they get right pricey.
    Hence why I measured the ones at the college and built my own. I will admit the commercial blowers add quite a bit to the prices. I'd bet at least 30% of the cost on those is simply the blower. You really don't need a big commercial blower like they have. A bath fan or other repurposed fan will do the job for a lot less money. If you are looking to go hand cranked though, you really don't have a lot of choices if you can't find an original used blower, and sort of have to buy a new one if you don't have access to a machine shop.
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    No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth!

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  4. #79
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    Re: Coal forge

    I have found bigger is not always better when talking about blower sizes on a forge. I have a pretty healthy blower on my forge with a waste gate installed in it that let's almost no air through and I do most of my forging with the waste gate closed, if I let the forge run wide open you can't get close enough to the fire pot to put material in or it melts away before you can get to it.

    In all honesty like DSW said, it dosent take much more than the output of a hair dryer to run a forge at operating temp. Even a 4" desktop fan at the end of your duct work would probably be sufficient.

    Hand crank fans are like gold around my area, and require more of your free time between heats to keep the coals burning which can become an issue for even an experienced smith at times!

    Good luck, and don't forget to think outside the box!
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  6. #80
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    Re: Coal forge

    thats a pretty impressive forge looks like it will get iron nice and hot are you just a tinkerer or are you like me and make parts with your forge. it looks good dude

  7. #81
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    Re: Coal forge

    A little of both. Mostly it's a hobby, but I find uses for it all the time making things for friends and myself. Like so many tools, once you get one, you find out how really useful one can be and wonder how you ever got along without one.
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    No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth!

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  8. #82
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    Re: Coal forge

    i do a lot of custom fab projects and i built one a few years ago just as a side project but i new as soon as i pulled my first piece of hot iron out of the fire i was hooked and now i find ways to use it on various projects for customers im planning to set some money aside to build a power hammer later on down the road

  9. #83
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    Re: Coal forge

    are you offering to do some side work for me?

  10. #84
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    Re: Coal forge

    DSW, What a beautiful project that is. Nice work. New to the site and am really glad to see a blacksmith section. Have a friend who teaches here in Ma. Looking to learn from him when time is available. Sorry to open an old thread but had to comment on the good work.

  11. #85
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    Re: Coal forge

    Thanks. The thread is still semi open as I'm still working on my design. Sadly this winter didn't leave me the time and weather conditions to get much done on it like I wanted to.
    .



    No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth!

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  12. #86
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    Re: Coal forge

    Yeah, This was a brutal winter. I live here in Ma. and as you may have heard we had a record snowfall all at once....Seems like if I wasn't plowing I was repairing watermain breaks..Looking forward to warm weather to get outside...

  13. #87
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    Re: Coal forge

    That is gooooood advice!!!! NOW that I finally got time to look at it. thanks. I think if I get to felling better that's what's I'm going to do. Got to go to a couple more Doctors that think they know what they are doing, but after that I should have some time.

  14. #88
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    Re: Coal forge

    Good looking forge, you might want to try an old dry blower, should have plenty of CFM and would likely need an air gate to stay away from welding heats when you didn't need it.

  15. #89
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    Re: Coal forge

    Thanks. I changed out the original blower for a commercial forge blower back around post 40. I had to add an air gate because the draft is so heavy that even choked down at the blower it was too much air most of the time.

    Biggest difference was changing from Anthracite coal to decent bituminous smithing coal. With the anthracite, I need to leave the blower running at medium most of the time to keep the fire going. With bituminous, I can shut the blower down, go grab lunch and still get the fire going again if I want without having to relight it. I also have WAY less clinker using the bituminous I got.

    One of these days I'll find some kid just getting started and donate a lot of the anthracite I have to them. It's crappy coal, but you can't argue too much with free.

    I also made up a temporary set of wheels I can slip over the legs so I can move the forge around easily by myself. I though I'd posted a pict of them on the forge, but maybe not. I'll dig thru my picts later and see if I can find one with them on from last years Grange Fair.
    .



    No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth!

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  16. #90
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    Re: Coal forge

    Nice setup but, I'm thinkin of going for the propane forge. Don't need anymore things to build. I can't find time for the stuff that has to get done.

    As for the Anthracite coal , save it for Christmas and put it in the wife and kids stockings.

    Here's a forge, http://www.chileforge.com/forges_jalapeno_details.html Cayenne - Oval two burner forge, NOT CHEAP !!!! Price $1099 plus shipping

    Attachment 1399021

  17. #91
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    Re: Coal forge

    E mentioned you were thinking about getting a forge. Raf here has one of their 2 burner Habanero forges. I've thought about getting one of those or possibly the Cayenne. I've heard good things about those forges. I'm hoping to get a chance to get up to raf's place and play a bit with his forge when I help him with his stick welds. If you get the Cayenne, just add it to the Ellis saw I already have dibs on. I'll just swing by and grab both at the same time.

    It's a tough call. It would be nice to have a long/wide forge to do things like the rings for wine racks. Both the Habanero and Cayenne both look like one of the best options out there for that. I wonder though how much shipping is going to add to the cost. I doubt these are light. On the other hand, having a wide shallow forge would pay for things like doing multiple bottle openers and cost a lot less. If I could find 2 or 3 people who wanted multiple bottle openers like the guy I had around Christmas, it would pay to grab something cheap like a Whisper Momma from NC to do them production style.

    A gas forge is on my list for this year, I just have to save up the funds. $5K in repairs already this year for the work truck has cut deeply into what money I had managed to save up over the winter.
    .



    No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth!

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  18. #92
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    Re: Coal forge

    I did PM Raf about his forge last year. As for picking up the ELLIS , you might as well take my machines too. You will need a trailer.
    I did talk with Stacie a couple of times. Shipping is right at $100.00. , I didn't ask the weight but it is listed around 65 pounds. The Cayenne - Oval two burner forge has standard features which are optional on the Habañero .They have great reviews and there is a waiting list of about four weeks . They also provide fire bricks to partially close off the opening .
    I talked with a '' PROFESSIONAL '' farrier about the NC forges. That what he uses and is happy with their NC Whisper Daddy #2 Forge with Open End Ports. That's what he has on all his trucks. Talk about a mobile shop and setup WOW ! I was with him a few times for a couple hours and learned a lot. I have watched other farriers at the neighbor's horse barn many times. Talk about night and day. It doesn't take long to pick out the real PRO. I'm still debating about them. The Chileforge has reviews that state they are the most efficient ones out there and only need to run at 3 to 5 psi . Tough call and big bucks.
    I did join Abana for their discount program with some suppliers and the I forge iron. I read some of your responses too . It saved me a few bucks already .

  19. #93
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    Re: Coal forge

    I was going to mention a proper blower, but there expensive. I've got one on mine, I bought a cast iron pot and built the rest, but I keep the air dam closed way down, I probably could have went smaller on the blower.

    BD1, there ain't no way, no how I'd buy that forge for that price. You can build a very nice Venturi or blown forge for way, way, less than that. You can get a good one here, http://www.hightemptools.com/forges.html Still overpriced, but more in range. Or for about 300$ or less build your own. For the blown forge the most expensive part is the blower, the ceramic blanket is pretty reasonable, and after multiple rebuilds I still have part of the original box of Kaowool left. Other than that, it's pipe fittings, a gas valve, some ITC-100 to coat the raw fibers, maybe some Satinite for the bottom to help protect against flux damage. The link I posted is where I got the burner assembly for mine, I got the blower from a blacksmith supply house. There are a lot of web sights on how to build a gas forge, there not hard to do at all, and a blown forge is easier than that. The problem I see with the forge you posted is the angle of the burners, ideally you want the interior round and the flame to roll around the lining producing a more even heat. Positioned as they are you get a bigger hot spot and cool areas.

    Here's both my gas forges, the vertical and the horizontal beside it. The vertical is good for damascus work as the flux dribbles out the bottom and doesn't eat the horizontal's up, borax flux at temp will eat through unprotected ceramic wool like water through cotton candy. They both use the same burner/blower assembly, I'm too cheap to have two when I can just swap between the two. The horizontal uses fire brick to close or open the opening as needed, as does the vertical. Eventually I'll have to replace the end of the burner, but it's just a piece of standard black iron pipe screwed into pipe fittings. Sorry for the low quality pic, it was taken at night and looks brighter than it is.
    Attached Images Attached Images  

  20. #94
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    Re: Coal forge

    Quote Originally Posted by BD1 View Post
    ......
    I did join Abana for their discount program with some suppliers and the I forge iron. I read some of your responses too . It saved me a few bucks already .
    BD1, you'll find a ton of info on gas forges over on IFI. They have an entire forum section on gas forges. Great blacksmithing site. DSW frequents over there as well.

  21. #95
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    Re: Coal forge

    Quote Originally Posted by shortfuse View Post
    BD1, you'll find a ton of info on gas forges over on IFI. They have an entire forum section on gas forges. Great blacksmithing site. DSW frequents over there as well.
    Thanks, Yes, I did go through ALL the forge posts and working on the tools. Only issue is on the old post you can't load the pics. '' Sorry, there is a problem
    Cannot find the page you requested '' I gotta look into that.

  22. #96
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    Re: Coal forge

    College has 4 NC forges. 3 Whisper Momma's and one of their long knife forges. Instructors comments on them are that they aren't bad for the money, but there are better units out there if you are willing to spend the money.

    I'm somewhat with you Bob. I bought a burner from Steve Geshmeir back after I was having issues with my pipe burner forge. I'd planned to pick up a 2nd one when I had funds available and start a 2nd gas forge build using insulation vs bricks like the 1st one had. Doing some more research, I can just about buy one for what it would cost me to build the one I'm thinking about. That's after already having one burner and the reg and hose parts. Granted we are talking one of the lower end less expensive units vs something like a Chile Forge, but I'm getting to the point in my life where I really don't want extra projects just to get to the point I can do what I originally set out to do.

    $100 in shipping isn't all that bad. I'll have to keep that in mind. I'd have expected more.


    I'll happily come out and get all your toys. E wants me to visit you all anyways at some point this summer. Will the 14' dump trailer work or do I need to bring the 20' flatbed? If need be I can leave the 115 gallon fuel tank at home to leave extra room in the back of the 11' body on the truck...
    .



    No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth!

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  23. #97
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    Re: Coal forge

    '' I'll happily come out and get all your toys. E wants me to visit you all anyways at some point this summer. Will the 14' dump trailer work or do I need to bring the 20' flatbed? If need be I can leave the 115 gallon fuel tank at home to leave extra room in the back of the 11' body on the truck...

    You'd have to spend the night, I don't think I could load it in a day ! Might be cheaper for ME to come by you !
    .

  24. #98
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    Re: Coal forge

    Quote Originally Posted by BD1 View Post
    Thanks, Yes, I did go through ALL the forge posts and working on the tools. Only issue is on the old post you can't load the pics. '' Sorry, there is a problem
    Cannot find the page you requested '' I gotta look into that.
    Sadly IFI had an issue when they "upgraded" the site last year and all the older picts are no longer accessible. The service provider they use simply doesn't seem to be willing to fix the bug and honestly after almost a year, I doubt they ever will. There were quite a few over there who were not at all happy about that situation, but most have learned to just live with it as there really isn't anything the general populace can do about it. the few that do load weren't directly loaded to the site, but posted up on something like photobucket. They want you to post picts to the site rather than post links, but them you can't get access to any of the old picts where people did that. Sad.

    I had almost 100 picts of the metal work over at the cathedral across from the college that will no longer load. It seems pointless to go thru all that work again to reload them, since the original comments would make no sense with everything out of order. Same goes with my forge build. I simply direct people to this thread if they want to see what I made.
    .



    No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth!

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  25. #99
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    Re: Coal forge

    BD1,

    X2 on what Doug said about IFI and the pictures. About the only thing you can do is to PM or post a request to the poster of the thread you are interested in to see if they can "re-upload" the photos to the site or email them to you. That has been successful in a few cases.

    The current condition of the IFI site software makes one REALLY appreciate the Welding Web site and it's software (and support).

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