I built a forge out of an old grill.

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I'm getting into knifemaking and I decided to build a little shop at my stepfather's cottage. I planned to make a forge around an old grill (Or whatever it was, you can see some rocks in a round formation on the right side and there was some old dish washing stuff around it.) Stepdad made some plans about how we should lay the bricks and they bought the fireproof bricks, cement, mortar and fireproof mortar yesterday. Last weekend I only got to clean the grill up a bit.
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As you can see, it was in horrible condition and we had to tear down most of it once we got the bricks. We started building on the day that I was supposed to do my taksvärkki work. What the hell is that, you ask? Well, in Finland back in the 1800's, torpparis, people who worked their own crops and house on a landlord's land, worked for their landlords for one day, once a year. The tradition has been carried over to Finnish schools, where one day, once a year, middle school kids find work and bring 10 euros to the principal and keep the rest of their wage. Anyway, me and my mother decided that building the forge was to be my work for the day, but because I had no experience with laying bricks level, I only cleaned up the area, carried the bricks from the car to the grill and mixed some cement and stepdad did the rest of the work.
We were left a brick and a half short, but this is where we're at.
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The hole on the front is where I'll remove all the ash from, and there is another hole on the left side where we'll put in an old hairdryer without a heating element.
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Now all we need to do is make covers for the holes and a worktable on the left side. I've heard that there is an old anvil at my grandpa's place, and I'll buy a cheap belt grinder and a CD player (I'd rather work with my heavy metal songs playing from speakers rather than in my head.) Whatever else I need to do, I can do at the existing woodworking shop in the garage.
 
Very nice...and doing a project as a family makes it even better.
The only thing I see that may be a problem is the air delivery system. A hair dryer won't deliver enough air for a large table forge like that. You will need a forge blower of some sort. The air flow needs to be regulated to control the fire pot.
Is it just open space under the grate? Normally there is a twyere (Too-Your) that delivers the air to the grate, and has a dump gate for the ashes.
Also, you will normally build up the area around the grate with fire clay to form the fire pot.
Here is a diagram:
http://en.wikipedia.org/wiki/File:Coal-forge-diagram.svg
 
That's exactly what I told him, and we have a vacuum cleaner that can be set up to blow, so I'll use that or a shop vac if the hair dryer doesn't work. The hole under the grate is about the size of half a brick.
 
That is cool! Improvise, overcome, prevail. Keep it simple and functional...always. Thanks for positng.
 
Read up on coal/charcoal forges and get some understanding of how the fire and the blower works.
You will need to control the volume of air as well as the pressure. It sounds like you just have an open chamber under the grate and are planning on pressurizing it with a big blast of air. That will work for making a roaring fire, but will be poor for controlling a forge.
 
No open chamber, the air hole is about the same size as the circular part of the grate.
 
Is there a dump trap/gate for the ashes? Or will you just plug the ash removal hole when in use?
How were you going to adjust the air flow below the grate? A drawing of the inner works would help.
 
I can only use paint, so excuse the crappy drawing.
The ash removal hole is the one on the front, and I'll screw on a thin metal plate over it when in use. I never thought of having to adjust the air flow, are you talking about how wide the air will spread or how much air gets in? Since I'm probably going to use a shop vac anyway, I can just open the hole on the tube if I need less pressure. When I'm igniting the coal with some sort of gas burner, the ash hole (wut) will be left open and the vac turned off, then the hole plugged and the vac turned on when the coal is burning stably.
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I'm still fairly confident it'll work.
 
I hope you at least used fire brick for the bottom of the forge. Red clay bricks will melt and turn to glass if they get to hot.
 
The air flow should be able to be regulated from a gentle whisper to a full blast. For a forge the size of yours that would be from 0 to 100+ CFM. Notice that I gave the air volume...not the pressure. Pressure is not needed...or desired. If you ask around, someone nearby may have an old hand-cranked forge blower. That is the device you really want to use.

If a proper blower isn't possible,try putting a choke valve in the air line. It will not be a perfect solution, but you could put a PVC valve in a section of 2" PVC pipe ( or whatever fits the shop vac hose) and use it to control the air flow. The problem is that the vac may get overheated when the valve is closed off more than halfway.
 
It works! I fired up some grill coal yesterday and the hairdryer worked beautifully. I used an old pipe wrench to hold my metal, an old vise for an anvil and a claw hammer. Didn't have any carbon steel laying around, so I heated up a 100-year old nail and forged it into a knife-like object. Not finished, but at least I know the forge works.
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The metal glowed much brighter than it looks in that pic.
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Wow, when I read the title I was thinking an old charbroil or something. That thing is sweet, and the surrounding area is beautiful! That seems like it will make a very nice, peace full place to work.

-Adam
 
Thanks. It is indeed peaceful and the forge really fits in. It's a large, bright and relatively pristine area with lots of trees, mossy rocks and it's by the sea. Couldn't really ask for anything else, other than an indoor toilet and running water.
 
Looks good. Wear some safety glasses to keep any soot or small air born embers from hitting you in the eye. A 12 volt hairdryer, cool. Try to rig it up so that you have an on off switch close to where your hands are while at the front of the forge.
 
You're hammering on a milling machine vise?

If it's not damaged, you may be able to sell, or trade it for an anvil.
 
Well damn. I'm not sure I can find anyone looking for one in Finland, but I found an ad put up by some woman for an old anvil, forge and tools. She says they're just gathering dust, so I think I could buy the anvil and tools for 50ish euros. Would this still be in usable condition?
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Well damn. I'm not sure I can find anyone looking for one in Finland, but I found an ad put up by some woman for an old anvil, forge and tools. She says they're just gathering dust, so I think I could buy the anvil and tools for 50ish euros. Would this still be in usable condition?
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Is that 90 Kilos?

or 90 pounds?

Either way, it's a great deal.
Don't hesitate.
 
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