The saga of my first forge weld

hillbillychuck

hillbillychuck

Joined
Jan 24, 2001
Messages
137
Well, for all of you who followed my last post on trying my first piece of damascus, I did manage to forge weld eight layers of steel together. But the process did not go without incident:rolleyes:

I staqrted with 9 layers, eight layers and a long piece of barstock on the bottom to use as a handle. Ground each piece of steel clean on both sides, stacked them up, and wired them together as per Jim Hrisoulas in his Damascus video. I put the wired up pieces in the forge and started them soaking. I think I was using wire that was too thin(tye wire). Before the peices in the middle were hot enough the wire started stretching and all the pieces started moving around. I fluxed real good and tried to line the pieces back up on the long piece of barstock, then I stuck it back in the forge all balanced on the long piece of barstock and brought it up to a welding heat. Pulled it out, set it on the anvil and gave it a series of taps. Put it back in forge, brought it up again tapped some more. Flipped the barstock sideways to see if it all welded and it had all welded except the long piece of barstock that was on the anvil. I am guessing that I did not pre-heat the anvil enough? So now I got a piece of steel with eight layers but no handle so I am going to take it to my neighbors with the torch and weld a piece of rebar on the end of it for a handle to draw it out.

Whew! What a journey for a piece of steel that looks just like a solid piece of square key stock:D

Thanks for the help y'all gave me. Ya shoulda been there, it was like "the keystone cops try to forge damascus"!

Chuck
 
Sounds like you had fun. When I start a billet I arc weld the 4 corners and weld a rebar handle on it.
 
Did you wonder how I knew about all the things you should do and not do in your last post Chuck.:D I tried the wire method and had the same result as you. At least you got a weld. I won't tell you how long it took me to get a rael piece of usable damascus:o If it hadn't been for the constant help on this board I would have given up. You get a true A+ for getting it the first time out. I would suggest you buy an arc welder at least. It makes the job a lot easier.
 
Been there done that.

I also arc weld the first layers but on just the handle end. Some times we up the gas pressure a little to get a hoter forge then turn it down when drawing out.
Some other guys may like to comment as to how they do it. Some time
we do things because they worked once and don't know any better.

When it comes to welding chain saw chain. I was lucky enough to be shown how to do it I heard about another group of guy all learnard guru's from the lets have go and have some fun brigade. They had fun but one came up with the Idea that there was too much crome in the links. So he told every one you have to grind off the teeth. Guys did it cause it worked.

I have made chain saw from brand new chain full teeth. Not lost a link. The moral of the story is we all have a few that go wrong but if you ever listen to me don't take it as the best way. There may be another guy out there with a better way.
Keep experimenting you may come up with the best way of all.
 
Heck I still use tie wire when starting a billet:eek: One thing is don't put a round bar on the bottom of the stack instead flatten the end of the bar and then put it in the middle of the stack and then add about four different pieces of wire wrapped around the stack one time and twisted.But keep the flame from hitting the wire straight on as it will burn up the wire before the billet is hot enough.;) Guess how I know..
You can always use my frontier style method of starting with two pieces of steel and after welding those sucess fully then add another until you get the layers you want.
As Cleston Synard once said...Grinding a bar of Damascus id like opening up a Christmas present,You never know what you are getting untill you take off the wrapping...
Great job at getting it the first try,keep up the great work.
Bruce
 
Cleston Synard. Man, I haven't heard that name in awhile. He was one of my heros when I first started all this maddness. He was a man way ahead of his time when it came to forge welding steel.

Bruce, have you heard anything about him lately?
 
He must be in his mid 80's. The last time I saw him was over in Winston/Salem at the knife show there. I think it was in '94 or '95 and he was in his late 70's then.

I don't think we ever talked knives when we would run into each other. Both of us being from South Alabama we would always talk about eating peas and corn and corn brread.

He has probably forgoten more about welding damascus then most of us will ever learn. He is truly a character.
 
i'm waiting for news about your steel bow project. not really an archer myself but the thought interests me. do you plan to add cam pulleys on them? might be a good idea. several english longbowmen developed scoliosis what with their 150+ pounds draw weight.

keep us posted, will you?
 
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