Stacy E. Apelt - Bladesmith
ilmarinen - MODERATOR
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Knifemaker / Craftsman / Service Provider
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- Aug 20, 2004
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This subject comes up regularly, so I thought I would make a thread on it. Later on I can move the thread to the forge info sticky. Please post your comments and suggestions in this thread. Try to use personal experience and knowledge instead of "I heard/read". If it is something you have from a good source, suppose, or theorize, state that.
1) The primary features of a forge are the insulation and the burner. Most other features are in the "nice to have" regions. These topics are pretty often discussed and can be found in a search. Anyone who has a suggestion or question is free to post/ask it on this thread. Round vs square etc. are als pretty well covered in previous discussions.
2) Safety is a big concern with a forge, so that is what I am going to discuss.
Fire Safety:
Forges should be built from a metal that will hold up to the wear and tear and heat. This is usually plain steel pipe or other tubing. They should also be mounted solidly on a steel cart. Thickness only needs to be enough to weld things to and support the insulation/refractory.
A forge should be at least 4 feet from any flammable surface or materials. This is important, as a fire
that starts in a wall or other place may smoulder and erupt hours later.
Do not out the propane tank closer than 6 feet from the forge, and have the hose running sideways from the forge ... never forward, back or underneath. Using a metal clad propane line is a very smart idea.
People worry about propane flowing after the power goes out. The simple solution for stopping the propane flow if the power goes out or at the end on the day is to install a standard fuel gas solenoid in the fuel line. It can be wired to a separate switch, the PID control, or the wall light switch. To use the light switch, install a DPST switch in the wall plate and use one set of contacts to control the solenoid and the other the lights. This way when you leave and shut off the lights, you shut off the propane tank. You should always shut the valve manually, but the redundant fail-safe is wise.
You used to read that the blower should be higher than the forge. This was to prevent propane from flowing down the burner pipe/manifold during a power outage and igniting when the blower turns on when the power restores. This is a very unlikely situation unless you don't shut off the gas valve when the power goes out. The solenoid mentioned above will solve that situation. The better reason not to have the blower above the forge is that when it is shut off hot gasses rise up the tube and can damage the blower or even overheat the gas inlet valve and cause a fire. Having the blower horizontal or under the forge is a far better arrangement.
3) Physical Safety:
Using a forge safely is simple and easy. Not doing things right can cause severe injury or a fire.
Wear the right clothes. Cotton fabrics, long heavy pants, long sleeve heavy shirt, leather shoes/boots that cover all the foot. Sneakers and sandals are just asking for trouble. Tie back long hair. If you have a bushy beard, avoid any flash of flame when lighting the forge. Forging gloves are a must for most all hot work. The hammer hand usually has a thinner leather glove and the tong hand a heavier gauntlet type glove.
All observers and helpers should wear the same type protective clothing. As much as bikini clad cheerleaders watching your muscles ripple sounds great, it isn't such a good idea ( especially if your wife finds out).
A sturdy and reasonably thick leather apron will protect you from the dragon's breath and accidental contact with hot metal. Do NOT wear a cotton shop apron, as they can easily catch fire. No frayed cuffs on your shirt sleeves for the same reason.
Wear eye/face protection ... ALL the time. Hearing protection is a very good idea, too.
Stand to the side as you ight the forge. Turn on the gas only after you have light the igniter. A long flexible stem fireplace or candle lighter is the best tool for the job.
Make some sort of support shelf to rest the work stock and/or rebar handles on. A simple "U" shaped piece of 1/2" round stock that round through some pieces of pipe welded on the sides of the forge will make an adjustable length support. Weld a 6X2" steel plate on the end to make a rest area. Pull it out or push it in as needed to support the work.
While HT is best done in subdued light, you want good lighting when working around the forge.
CLEAR the floor and area 10 feet around the forge of all trip hazards, electric cords, and projecting objects. Sweep away and wood dust or paper scraps. When working damascus, the area needs to be cleared for 20 feet or more.
Don't work in the shop when you have been drinking alcohol, and don't drink alcohol when you are working in the shop. Drugs and such obviously are even more verboten.
Don't work when too tired, distracted, mad, upset, overly sad, or depressed.
Don't let the kids play in or around the shop when you are working with power tools or the forge.
Music in the shop is fine, but headphones should be used with discretion. If you are jamming to Metallica and can't hear someone telling you your shop is on fire that is a bad thing!
Try to place equipment so the entrance door and open areas are in your view. This may prevent getting startled while working with dangerous equipment.
OK, that is a good start. Comments and additions.
1) The primary features of a forge are the insulation and the burner. Most other features are in the "nice to have" regions. These topics are pretty often discussed and can be found in a search. Anyone who has a suggestion or question is free to post/ask it on this thread. Round vs square etc. are als pretty well covered in previous discussions.
2) Safety is a big concern with a forge, so that is what I am going to discuss.
Fire Safety:
Forges should be built from a metal that will hold up to the wear and tear and heat. This is usually plain steel pipe or other tubing. They should also be mounted solidly on a steel cart. Thickness only needs to be enough to weld things to and support the insulation/refractory.
A forge should be at least 4 feet from any flammable surface or materials. This is important, as a fire
that starts in a wall or other place may smoulder and erupt hours later.
Do not out the propane tank closer than 6 feet from the forge, and have the hose running sideways from the forge ... never forward, back or underneath. Using a metal clad propane line is a very smart idea.
People worry about propane flowing after the power goes out. The simple solution for stopping the propane flow if the power goes out or at the end on the day is to install a standard fuel gas solenoid in the fuel line. It can be wired to a separate switch, the PID control, or the wall light switch. To use the light switch, install a DPST switch in the wall plate and use one set of contacts to control the solenoid and the other the lights. This way when you leave and shut off the lights, you shut off the propane tank. You should always shut the valve manually, but the redundant fail-safe is wise.
You used to read that the blower should be higher than the forge. This was to prevent propane from flowing down the burner pipe/manifold during a power outage and igniting when the blower turns on when the power restores. This is a very unlikely situation unless you don't shut off the gas valve when the power goes out. The solenoid mentioned above will solve that situation. The better reason not to have the blower above the forge is that when it is shut off hot gasses rise up the tube and can damage the blower or even overheat the gas inlet valve and cause a fire. Having the blower horizontal or under the forge is a far better arrangement.
3) Physical Safety:
Using a forge safely is simple and easy. Not doing things right can cause severe injury or a fire.
Wear the right clothes. Cotton fabrics, long heavy pants, long sleeve heavy shirt, leather shoes/boots that cover all the foot. Sneakers and sandals are just asking for trouble. Tie back long hair. If you have a bushy beard, avoid any flash of flame when lighting the forge. Forging gloves are a must for most all hot work. The hammer hand usually has a thinner leather glove and the tong hand a heavier gauntlet type glove.
All observers and helpers should wear the same type protective clothing. As much as bikini clad cheerleaders watching your muscles ripple sounds great, it isn't such a good idea ( especially if your wife finds out).
A sturdy and reasonably thick leather apron will protect you from the dragon's breath and accidental contact with hot metal. Do NOT wear a cotton shop apron, as they can easily catch fire. No frayed cuffs on your shirt sleeves for the same reason.
Wear eye/face protection ... ALL the time. Hearing protection is a very good idea, too.
Stand to the side as you ight the forge. Turn on the gas only after you have light the igniter. A long flexible stem fireplace or candle lighter is the best tool for the job.
Make some sort of support shelf to rest the work stock and/or rebar handles on. A simple "U" shaped piece of 1/2" round stock that round through some pieces of pipe welded on the sides of the forge will make an adjustable length support. Weld a 6X2" steel plate on the end to make a rest area. Pull it out or push it in as needed to support the work.
While HT is best done in subdued light, you want good lighting when working around the forge.
CLEAR the floor and area 10 feet around the forge of all trip hazards, electric cords, and projecting objects. Sweep away and wood dust or paper scraps. When working damascus, the area needs to be cleared for 20 feet or more.
Don't work in the shop when you have been drinking alcohol, and don't drink alcohol when you are working in the shop. Drugs and such obviously are even more verboten.
Don't work when too tired, distracted, mad, upset, overly sad, or depressed.
Don't let the kids play in or around the shop when you are working with power tools or the forge.
Music in the shop is fine, but headphones should be used with discretion. If you are jamming to Metallica and can't hear someone telling you your shop is on fire that is a bad thing!
Try to place equipment so the entrance door and open areas are in your view. This may prevent getting startled while working with dangerous equipment.
OK, that is a good start. Comments and additions.
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