Quality Forge Build Or Buy.... How Would You Do It?

Bruce that is looking good! I'm a big fan of your work.

The way it is built looks ideal for holding heat. Are these forges mostly used for forge welding?

Daniel,
The blown forge is used for all forging temps from 1600f to 2350f if the blower is matched to the size of the inside area of the forge. Simply adjust the propane and fan for the desired temperature. This one will idle along with only 1 1/2 psi at 1900f for days.

I've discovered after many years there is no reason for an oversized forge. It was like driving a full sized car back in the 70s when cars got poor mileage. The smaller more efficient forge only needs to heat the billet or blade so theres no need for huge. 12" tall and 12" wide with 1" of koa wool and 2" in the roof will do it. The floor just needs a couple inches kitty litter which takes up extra space and catches dripping flux.

Notice the bottom is removable not the top like most all vertical forges I see. This makes it a snap to seal the top inside when coating the kao wool with satanite and keep valuable heat from escaping.

I can put 2 billets in this one at one time because of the 4" door opening.
 
Daniel, I have seen some of your work (very nice) and have read many of your posts giving helpful information to others. So in an effort to give back to Bladeforum members who have helped me along the way, I'd like to help you out the best I can. I have access to a lot of materials, both stainless and carbon steel pipes, large and small diameters. I'll check and see what pipe remnants I have that you can make a reasonably good sized forge with, and let you know. I can also help fabricate some parts for you, as I am an experienced fabricator and welder. Let me know what you're in need of and what size, and I'll see what I can do. Your only cost would be for shipping the material to you. Let me know if you're interested.

Rick

Wow! I just can't say enough about how generous that is. I really appreciate you thinking of me, that is too cool! :D PM Incoming! :D Thanks very much.

Your forge build looks incredible, very nice work. :cool:
 
Daniel,
The blown forge is used for all forging temps from 1600f to 2350f if the blower is matched to the size of the inside area of the forge. Simply adjust the propane and fan for the desired temperature. This one will idle along with only 1 1/2 psi at 1900f for days.

I've discovered after many years there is no reason for an oversized forge. It was like driving a full sized car back in the 70s when cars got poor mileage. The smaller more efficient forge only needs to heat the billet or blade so theres no need for huge. 12" tall and 12" wide with 1" of koa wool and 2" in the roof will do it. The floor just needs a couple inches kitty litter which takes up extra space and catches dripping flux.

Notice the bottom is removable not the top like most all vertical forges I see. This makes it a snap to seal the top inside when coating the kao wool with satanite and keep valuable heat from escaping.

I can put 2 billets in this one at one time because of the 4" door opening.

Thanks again, that sounds very good.

I'm glad you mentioned the removable top, that makes a lot of sense. I really appreciate the help!



Good lookin forge, Bruce.

I agree!
 
Update!

I should have everything together for a build very soon! I'll be sure to document the process here in hopes of returning some of the help I have gotten. Thanks guys!
 
Dan, so how's it coming? I'm wanting a forge as well, but all the information is overwhelming and every time I think about buying one, someone says I can build it for 1/5th the price. But since I'm working 6 and 7 days a week, have a rental house, have a mostly independent 95 year old Grandmother in my life that gets my time as well, I'll probably never build a forge or any other piece of equipment. If I ever take this hobby past the reading stage, most equipment will need to be turn key. But since turn key is much more expensive than DIY, I'll probably just sit back and watch.

Buying your first forge is not a bad idea. Being new to it, you probably don't know what features you "want", and unless your time is free, it's probably cheaper just to buy one turn-key.

I'm curious as to how your getting along or what choice you made if any. As others have said, you have nice work already. It's interesting that you already have a craft background with you and your wife before getting into knives. I weaved chainmail jewelry for awhile; that was very fun, but hard on the eyes and wrists.
 
Last edited:
Dan, so how's it coming? I'm wanting a forge as well, but all the information is overwhelming and every time I think about buying one, someone says I can build it for 1/5th the price. But since I'm working 6 and 7 days a week, have a rental house, have a mostly independent 95 year old Grandmother in my life that gets my time as well, I'll probably never build a forge or any other piece of equipment. If I ever take this hobby past the reading stage, most equipment will need to be turn key. But since turn key is much more expensive than DIY, I'll probably just sit back and watch.



I'm curious as to how your getting along or what choice you made if any. As others have said, you have nice work already. It's interesting that you already have a craft background with you and your wife before getting into knives. I weaved chainmail jewelry for awhile; that was very fun, but hard on the eyes and wrists.


Look out soon, I'm about to get the build together. I have my parts ready to go besides some blower fittings/hose. I consider buying a welder too... lol I get carried away! I still debate using bricks, board, castable refractory or inswool/metal for the ends. But that is easy... I'll likely use brick to keep it versatile.

I also needed a better place for my Forge/Foundry gear and poured a concrete table base a few days ago... it is looking good and won't catch on fire! This concrete thing is pretty interesting too! (note to self - stick to the forge!)

The build itself should not take long, it took me part of afternoon to build my smaller forge and maybe a couple of hours over a few days to line it. I'm glad I built it and have learned a lot... well worth my $30 expenditure for the forge body. Loads of fun too!

I'm building a very nice blown forge and like to research things quite a bit. It will also get a lot of use. So far I'd say for most people it would be great to buy a Whisper Momma or the likes. For the money and time you probably can't beat it. Portable too!

I started researching and found the subject of forge building to be a lot of fun. I could care less about building grinders or fixtures but this is really enjoyable for me.

My $30 body mini forge works great and with the Atlas burner it was pretty much plug and play. I need to do another video showing how I usually run it with the ends nearly closed off.

Price... hah! :D I consider my forge a hot rod though. It has a real forge blower and is made to last a lifetime besides changing out the lining. Add up everything you need for a decent blown forge and it is not cheap if you have to buy everything. On the other hand if you really look around you can build something very nice for a decent budget. I found that my small forge is actually really big too... no need to build something huge unless you just really want to go that way.

That's cool on the chain mail! I finally gave in and wear 1x glasses for that sort of detail work, an Optivisor is next! It's good to stay busy making stuff and having fun! I think with your schedule a plug and play unit would be nice and save you a lot of time... get right to forging!
 
Last edited:
Hey guys! I just wanted to bump this one to let you know that the forge build is still on.

I have purchased a welder, a bit of steel, 112 CFM Forge Blower from blacksmithdepot, refractory supplies, etc. I'm needing a couple of pieces of steel for the ends and I'll be back on with the build.

I've been about as busy as it gets with about 100+ knives and tools made over the last couple of months... I just completed a really big order so look out for lots more demo work and fun stuff from DFK!
 
The forge build is back on!

I had to get back on cranking out the knives then Winter hit me before I could build a Smithy.

I've since acquired a band saw and grinder to go along with my other fabrication tools o build the forge the want I want. I just got a load of steel from the scrap yard to compliment the forge body and got to work!


Here's where I am at... I spent yesterday welding everything up. That's the back of the forge, I'll get pics of it all when there is better lighting. The front looks almost the same and there is a flange I tapped for my burner.







I'll line it today and get a coat of Satanite on! I'm doing at least 2" of inswool.
 
looking at the pic... those hard bricks will fit sideways and seal up better than it looks. I'm going to cut some new bricks to size with my rock saw though as they will fit better. I had it set up to fit the bricks upright but like this better.

I also forged a shelf in the angle iron for each end.. so I used a smaller forge to help build this. It's hard to see in the pic but I'll get more.
 
Take two lengths of 1/2" pipe and weld along the sides as slides for a pull out front work rest. Make the slide from two pieces of 3/8" round bar and a work rest welded across them. The rest should be at the height of the front port, so you may have to weld a couple pieces of square tubing or other bracing across the rods to get sufficient height. This will allow supporting work of all lengths. It is really useful for working long bars and things locked in tongs.
 
Take two lengths of 1/2" pipe and weld along the sides as slides for a pull out front work rest. Make the slide from two pieces of 3/8" round bar and a work rest welded across them. The rest should be at the height of the front port, so you may have to weld a couple pieces of square tubing or other bracing across the rods to get sufficient height. This will allow supporting work of all lengths. It is really useful for working long bars and things locked in tongs.

Will do! I started to yesterday but ran out of time, that's probably my last step of fabrication.

I lucked out at the scrapyard and got loads of tubing, forge bodies, a huge 6" pipe for a vertical quench tank... even a big stainless keg I have deemed too nice for my vertical forge build. I'm debating messing with a propane tank for the vertical forge build.
 
Back
Top