Recommendation on a basic forge setup

[lamontjb]

So I recently PCSed to Korea for 18 months on assignment and have been assigned to the "blacksmith battalion". Without putting two and two together (I didn't realize the units motto was the blacksmith), I announced that I am a hobby knifemaker. Long story short, I got a "hey we need to talk about that one day" from a key person and suspect that I might be asked to make a blade for the unit (which I love doing by the way). However, I'm at home with my shop of tools and such AND I have only done stock removal.

So... I got to thinking about the possibility of making a knife while I'm here and moving towrds forging my first blade... with certain conditions. 1) I don't go over budget (which will make the wife mad) and 2) I would prefer to make a finished looking piece.

So I have to go back to basics here while venturing into unknown terrority (forging) and would like some advise.

First, I have two forges at home which I believe I could get my wife to send the smaller one that I have. It is an old freon tank build that I havent used in probably 4 years so I might need to re-wall the inside. I hope shipping isnt that much and I know my wife wont be thrilled about taking that to the post office... lol. But that would be a great start. I have already asked her to send me two of my forging hammers, the smallest one I have and one of the larger ones.

Can someone give me advise on what metal I should use to make a good blade (plan to make hidden tang with pommel). I also considered asking her to send me one of my railroad spikes because that seems like it would be pretty simple.

Second, in regards to sharpening the blade after heat treat, what should I use? I normally use my KMG but I'm not going to have that anytime soon. Maybe a course stone?

Will continue to mull this over but would love some feedback since I'm already excited that I might be able to make a blade while I'm here (also, they have a 50 KG anvil which I plan on using.... its better than nothing).

 

[bkstabler]

Look up brake drum forges on YouTube. There are a few vids on there showing you what you'll need. Basically you just need an old brake drum from a junkyard, some pieces of 2 inch black iron pipe, a flange, end cap, bolts, and a hair dryer. I figure if you can get your hands on a big truck's brake drum, you could go even bigger scale. There are prob better forges out there you can make, but it's easy and cost me about $20 and will heat white hot

 

[Brian Ayres]

Get a couple pieces of 1080/1084. It'll be easiest to heat treat. Then, soak your blades in vinegar to remove the forge scale and finish the bevels by draw filing them the rest of the way in after forging. You should be able to forge it pretty close with some patience. Honestly, I'd venture to say there will be a 4-1/2" or larger angle grinder around, use it to carefully rough in/ clean up your bevels close and clean up the forge scale. Then, move to draw filing.
Also, instead of the freon tank, get a couple soft firebricks if your only doing a couple knives. Find a torch locally and make a small 2 brick forge. Just be careful not to overheat the edge.

 

[mgysgthath]

If you go coal be careful not to get it too hot, because it will literally melt.. I've lost a knife or two that way