The walls of the gas forge doesn't have to very thick at all. One of mine is .300 and the large one is .120. What matters is the insulating material inside. I use an insulating blanket of about 1" and about 3/8" to 3/4" of satanite refractory. I do have a cap welded on one end and the other end is open. I lay it horizontal and just put bricks in front of the open end. I usually leave about a 2" square opeming for my material and more if it is required. This is the one that I use to make damascus in and forge with mostly. It is 8" OD and has about a 5"dia. opening. The forge is about 15" long and the burner comes in at an angle at the back. It does a very good job of heating. This is one propane forge that got hot enough to "burn up" a piece of damascus on the end. I lost about 1/2 of it due to not paying attention.
The band saw blades make good damascus when mixed with just about anything. They should be about .7% carbon and have enough nickel in them to have good contrast. If you have a hot saw or a thin bladed grinder, you can cut blade blanks out and do the stock removal thing. They are verrry hard to drill even when heated. So, burn a small hole and braze it closed. Be careful not to get the cutting part of the blade more than blue. Drill a hole in the brass. Another way is to cut a larger hole and when you put the handles on, use enough epoxy to fill the holes and keep the handle from getting loose.
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Ray Kirk
http://www.tah-usa.net/raker