Frontier Damascus how to?

etp777 · Feb 28, 2003

OK, I've seen mentioned many times the term fronteir damascus, and I even throw my carbon steel scraps(and jewelers saw blades, etc) in a can for future use at this once I start forging. BUt I can't seem to actually find a how to on this anywhere. I get how regular damascus or cable damascus can be forged, as you can weld the ends to hold the material together while you heat and pound it. I don't get how you would hold the materials for frontier damascus together while you worked though.

Frontier Forge · Feb 28, 2003

Try doing a search for powdered metal damascus tutorials. Excuse my crued explanation. ist you take a mild steel thin wall tube say 2 x 2x8 weld an end on it, fill the little can youve made with powdered 1084,and your damascus scrap, fill the can help it all settle by tapping the can or vibrating or compacting, drop a small wood chip size of a pea on top of the powder mix, weld another end on so you have a sealed can,weld a handel to the end on the unhandeled end make a weep hole to vent gasses or leave a weld void, stick the can in the forge bring it up to temp so it looks like a cube of butter, and forge it out trying to keep it square as you go, best done with a press, I imagine you'll end up 1x 1 x 14 at that point you could accordian cut it on the sides with alternating band saw cuts from the side say 3/4 an inch apart, stagared from to sides, heat to yellow grab the two ends with pliers and pull it aapart to make it somewhat flat, forge to make flat. The possibilities are endless. I personall have not done this but have helped three other knife guys create, billet this way..

Belstain · Feb 28, 2003

Another method that gives neat results and is the easiest way to forge weld is to start with a chuck of barstock maybe 1 1/4" x 1/4" x 3' long and start welding random scraps of steel on the last 6 inches or so alternating both sides and you'll have a cool frontier damascus with a solid core. This is a good method to learn how to forge weld because you are only welding small pieces.

Bruce Evans · Feb 28, 2003

Thats the way to do it..One piece forge welded on a bar at a time anysize scrap piece will work,Heck When I started making the Frontier style Damascus everyone thought I was crazy but it looks cool,Throw anything you want in the mix,just lock up your tool box before you use up all your wrenches making Damascus.Nails,nuts and bolts also work great,The cutoff ends from other bars of Damascus also work great.You can spot weld with a arc welder each piece but that takes the fun out of it to me,I like the challenege of making a ball bearing set on the piece and stuff like that.It also helps if you pick up some of the cast iron shaving from the local mechanic that he gets when turning brake drums.Mix some of these with Borax or just spoon some on when trying to hold a piece on the bar,this will help when a piece is hard to weld and adds carbon to the steel...

The reason I named mine Frontier was it sounded better than Junk or scrap Damascus...On the Frontier it was the aprentices job at the end of the day to weld up all the days scrap into a bar that could be used the next day thus the term "Frontier Damascus"

Bruce

Steven Roos · Feb 28, 2003

Originally posted by Frontier Forge
...make a weep hole to vent gasses or leave a weld void...

That is one point that Bill Herndon really emphasized when I was over at his shop a couple weeks back. He said if there is a little moisture trapped in there and it is sealed, "You've got a bomb!"

Belstain · Mar 1, 2003

I just knew I was right

Jeez Bruce great minds really must think alike, I even have a big can of brake drum shavings just for that reason

If you work with stainless be sure to keep it out of your mix. It doesn't work too well.

Bruce Evans · Mar 1, 2003

Cool Belstain...Maybe it's because I am originaly from Oregon

Stainless will weld in the billet,you just have to remember (spelling

lack of sleep) That it air hardens and thus you cant stretch it out like you do carbon steels unless you keep it above critical at all times that you are forging it.I have done it and it looks really cool in a mix but it takes allot more patience to work it.Cleston Synyard has added stain;ess to his mix for years,and will be at Batson's hammer in this spring showing ow to do it.
Bruce

etp777 · Mar 1, 2003

Thanks for all the input you guys. Got plans in a coupla weeks to go to friends shop and give this a try now. Doubt it'll turn out well, and damascus, particularly frontier damascus like this probably isn't smartest/easiest thing for my first time forging, but I'm sure I'll have a blast either way.

Bruce Evans · Mar 2, 2003

Good Luck

Actually,If you do the Frontier style one piece at a time it is the easiest way to learn how to make Damascus as you are only having to weld two pieces together and then once you have mastered that you can weld anysize stack you want,but first you have to learn how to make the weld..
Have fun and let us see how your first attempt at Damascus turns out.
Bruce