Lining an Ellis 8HT forge

silver_pilate

silver_pilate

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Oct 30, 2002
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Well, my forge is here (an Ellis 8HT horizontal forge), but I'm missing a box that I'm assuming has the ITC-100 and the lining instructions. As it is, I have the kaowool, satanite, and some Mizzou (for the floor, I'm assuming).

As I have a free weekend, I'd like to get started on it, but with the Ellis' away from the shop for the holiday, I need some guidance.

My thoughts are that I need to cut a single layer of kaowool (about an inch+ thick) to line the forge body and the end caps and cup out the openings for the front and back as well as for the burner and TC.

Next, I'm thinking a 1/4" layer of satanite over all of the exposed kaowool.

Any good instructions on mixing up the satanite? I've got a two pound bag. Do I need to mix all of that up to a plaster? After I've got the satanite applied, I'll let it dry before applying the ITC-100 (when I finally get that in).

And as for the mizzou, I'm assuming that is for the forge floor. Should it be laid last, or should it also be ITC-100 coated?

Having never done this before, I'd appreciate a little guidance from the many of you who have done this many times. Thanks!

--nathan
 
I definatily cannot help you out here but I really hope you take/post pics along the way; I'd like to "watch!"
 
I am about to do the very same thing to my forge, and would appreciate the same advice you are asking for.

Milt
 
You can probably find instructions for mixing the satanite using a google search. I recomend that you mix small batches to start with, to give you enough working time. Any delays or mistakes can be very stressful when all of your satanite is hardening in the mixing tray.
The sides and top may need two thin coats with a sticky mix so the satanite dosen't sag off before it sets. The surface of the inswool is not really rigid or stable enough to provide good backing for the satanite so it helps to start at the bottom and work upwards, and be gentle so the inswool dosn't start coming apart underneath the satanite. And wear a respirator, the inswool fibers and satanite dust from mixing are not good for you.
 
I just went looking for instructions Darren emailed me a few years back, but I can't find them. What I can do is tell you how I've relined mine (and it's been done a few times since I got it...)

- cut out circles of inswool for the front and back. Don't worry about holes for the openings yet, just cut circles.
- cut a piece of inswool about 12"x25" That will wrap around the inside
- put one circle of wool in the rear of the forge.
- roll up the big piece into a tube and slide it in
- Mix up some satanite until it's about the consistency of sour cream. Add water slowly so you don't get it too runny. Also, you will not need all of the satanite Darren sends you. Mix up small batches and only use what you need. He usually sends enough to do a couple of linings of the forge.
- take a sharp knife and cut away the circle for the rear exit of the forge
- spray down the inswool with water until it's damp. this helps the satanite stick.
- spread the satanite in an even, thin (about 3/16" thick) coat on the wool
- fit the round piece for the door and cut out the opening.
- coat the wool on the door.
- Let dry 24 hours.
- Repeat satanite coating
- Repeat drying cycle
- Mix up the mizzou to about the same consistency as the satanite
- Start laying down a layer of mizzou that extends about 1/3 of the way up the side of the forge interior. Ultimately you want this layer to be about 1/2 thick
- Let dry 24-48 hours
- Close everything up, and test fire the forge. You'll probably see steam from the wool/mortar drying. Don't go all the way up to temp, just enough to dry the wool out, etc.
- Let the forge cool down.
- Fire again and run up to temp.
- Cool the forge down.
- Patch in any cracks with more satanite.
- let dry, then rock-n-roll.

-d
 
Sounds good, deker. Thanks for the help!

A question about the mizzou. You said you want the mizzou (for the floor, correct?) to be about 1/3 of the height of the forge? And then ultimately about 1/2? Could you clarify that for me?

Also, is ITC-100 not part of the lining? Maybe I'm not missing anything after all, though there is a box missing from my order. I was assuming that Darren included that as part of his lining system.

--nathan
 
The ITC is intended as a top-coating that reflects heat back into the forge chamber that would otherwise be absorbed by the satanite and insulation underneath. It is applied as a thin coating, kind of like paint over stucco.
 
Nathan, in the spirit of the Season I'll spare you the trouble of lining your new forge. You just ship that thing over to me and I'll line it and test run it for a couple of years.... :D
 
I'd love to, Frank. But it's been a long road to get to this point, and as I had mentioned in my first post, Darren is away from the shop for the holidays and isn't returning emails until he gets back (which I'd imagine would be Monday). I will hopefully hear from them about the status of my missing box and about the instructions then. I was hoping to get some work done tomorrow while I have a free day, so I needed some guidance to make sure I was headed down the right path as far as lining this thing. :)

--nathan
 
silver_pilate said:
Sounds good, deker. Thanks for the help!

A question about the mizzou. You said you want the mizzou (for the floor, correct?) to be about 1/3 of the height of the forge? And then ultimately about 1/2? Could you clarify that for me?
Click to expand...


Oops, I meant 1/2" thick. So, make it 1/2" thick, extending from the bottom up the walls to about 1/3 of the height of the forge. Make more sense now? :)

-d
 
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