Arctic Fire - Making Tamahagane in Alaska Bill Burke and David Mirabile show knives

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I was fortunate this year to receive a grant from the Rasmuson Foundation to fund some projects I have really been wanting to do for a while. The Rasmuson Foundation is an organization dedicated to furthering arts in Alaska. The projects I included in my proposal were; Build a tatara and make tamahagane, work on my journeyman smith certification, build a rolling mill, and take engraving classes.

First project - Tamahagane

I gathered up all the necessary supplies from a list given to me by Bill Burke; 4000 pounds of charcoal, 600 pounds of iron ore sand provided by David Mirabile (gathered from an un-named creek near his place), 150 lbs GROG, 150 lbs of fire clay, three hundred fire bricks salvaged from a WWII missile site near Fairbanks by my buddy Mike Bracken, 30 cinder blocks and a piece of hardy board to name just a few of them.

With the elements gathered, all we needed was someone to run the show, Bill Burke - the Sensei of American Tamahagane making. As you can imagine, people like him don't come cheap, but they can be bought. His weakness - fishing. My event was going to be during his 25 anniversary to his wonderful wife Patti, so I sweetened the deal with a 5 day deep sea fishing trip and they were in.

The Fishing Trip

We fished out of Seward Alaska aboard my boat the Non-pelagic Squid

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Bill and Patti Burke with on of the few fish Bill was able to catch.

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From left to right; First mate Mike Bracken with a China rock fish, Bill Burke and Bob Hook, Fairbanks Journeyman smith, both with silver salmon and Daniel O'Malley of Blade Gallery.

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Part of a days catch that included silver salmon, china rock fish, copper rock fish, greenling and black rock fish. We brought home limits of fish every day despite Bill's awkwardness with a fishing pole.

Building the furnace

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Bill laying the bed for the tatara - the traditional furnace for making tamahagane.

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A fire is started in the bed to preheat it and help dry the furnace.

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While the base warms up we get started chopping the charcoal. It needs to be chopped to about golf ball size.
 
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Here is a thread to subscribe too :thumbup: Thanks.

Keep showing more please.

Ray
 
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We build up the sides, mudding both inside and outside as we go up.

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Pretty close to the final courses.

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The brick work is done and Bill fires it up with wood to dry the mud.

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While the furnace dries, we rig up a way to dry the ore sand that is still damp from the creek bed it was harvested from.

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On the morning of day two we start to plumb the tueres

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We took time out to celebrate Bill and Patti's 25th year anniversary, and have a piece of cake.
 
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The plumbing is done and the furnace is fired up. first we fill the tatara with charcoal and then follow every 18 minutes with a coffee can of ore sand and a garbage can of charcoal. We do this continuously over night till the morning of the third day.

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The charging goes on through the night, the Bobcat is used to provide a roof to keep the rain off.
 
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After the fuels are all burned down, the tatara is pulled apart.

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This molten mass is mostly glass from the silica that was in the ore but somewhere in there is the metal we are seeking.

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Bars and hammers are used to break apart the mass. Then we went through it with magnets to find all the tamahagane.

More to come.
 
Mark, thanks for taking care of two of the greatest people. Bill and Patty. Also looks like a great cook. I hope to see a katana at blade from your cook. I will have one from our last year cook. At least a finished blade. Maybe not a finished complete package. Thanks for. Showing pictures. Gary
 
I talked with Bill in KC and checked out a piece of that steel he had on his table. Quite a process and quite a great bunch of folks....looks like a great time was had by all.

Anyone make something out of it yet?
 
Mark, thanks for taking care of two of the greatest people. Bill and Patty. Also looks like a great cook. I hope to see a katana at blade from your cook. I will have one from our last year cook. At least a finished blade. Maybe not a finished complete package. Thanks for. Showing pictures. Gary

Hi Gary, we had a great time. Wish you could have been here. Not sure if I will have time for a katana but I will make something.
 
I talked with Bill in KC and checked out a piece of that steel he had on his table. Quite a process and quite a great bunch of folks....looks like a great time was had by all.

Anyone make something out of it yet?

We have started, Bill has some steel from it, I do and David does. We will keep you posted.
 
This early portion of the thread is like a great trailer for a blockbuster movie.

Subscribed!

Coop
 
What a great project. I hope enough people remember how to do stuff like this when our virtual lives suddenly go dark.
 
Really nice to see the "community" side of a great project. It just seems right to pursue such a back to basics effort in Fairbanks. Thanks for sharing.
 
Thanks everyone for watching.

Here are some shots of the progression from raw materials to the finished product.

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This is the ore sand in the raw form, it has been screened to get just the fine stuff.

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Here is some of the tamahagane. We smelted 400 pounds of the sand and ended up with 25 pounds of steel for a yield of about five percent.

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A bar of the tamahagane after it has been refined. After being formed into a rough bar it was folded and forge-welded to itself 14 times.

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The first blade blank I forged from the tamahagane, a skinner.
 
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Thanks for posting these shots of the 'finished product'.....looking forward to seeing your knife. :cool:
 
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This is the second blank I forged from the bar, a drop point hunter. I plan to use spalted birch for the handles and copper from the Kennekot area for the guards.
 
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Great thread, Mark, many thanks.
So looking forward to seeing a finished knife.
This should be really something. :thumbup:

Doug
 
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