When working with these ceramic material wear a good quality respiratory and vacuum up any fibers after cutting. For instance, someone who makes swords requires a much longer propane forge than someone who wants to produce small blades. As a blacksmith gas forge the atmospheric forge is a good starter gas forge. Vertical (a la Don Fogg) or horizontal? To cut the brick a wet saw was used, other methods are using a chisel and hammer but the bricked I used were too brittle to cut using that method. Finalize the plan. I would appreciate some expert input on several questions. for a typical minforge or a pint for a two burner forge. I want to get into blacksmithing and bladesmithing, you know, making knives, daggers, swords, maces, war hammers and the lot... Do it!!! How to Build a 30 Kilovolt Wimshurst Machine! How much or what volume of Propane Gas is used to heat up your Propane Forge during an average use? This video and instructable has been an amazing help. Laying an extra inch of kaowool, etc. 1. I LOVE this instructable. I use the propane forge on a work stand. After the tank had cooled, there was no more mercaptin smell in the tank, and I used a cutting wheel to finish the job. Post Jan 23, 2011 #1 2011-01-23T16:56. Using soft firebricks to make a rectangular chamber, then wrapping it in 2 layers of Kaowool makes a cube that fits perfectly in the 13 inch diameter pot. Your previous content has been restored. A: The answer to this question has a few answers. I can get about four hours of continuous use until the temperature of the propane gets too low, the flow stops. A: Yes you can, however a forge with a casted liner is usually very inefficient. I believe the ratio is 7:1 (area to area). Now it only really would take about 45 minutes with my setup to get hot enough to melt brass. I cut the ends off both ends of the tank using a thin kerf cutting disc on a mini grinder. To keep the inside of forge so it is accessible a removable front opening was installed. I want to melt 260 Brass scrap from cut-up materials in a small ?rectangle? Also be aware that the forge and it's lining is only half the story. Allow the forge to gently cool off . 292. There’s going to be some fun times ahead, learning and making all sorts of cool things!The kit worked out awesome! on Introduction. To make a template a piece of plastic was draped over the opening and traced out. If I used the same layers of the blanket. For Christmas I am getting my husband all the supplies he needs to build a forge! Witch is a little longer and the inside diameter then the air tank. Larger melters can use lift off bodies with counter balances or the diagonally split clam-shell type similar to those used by potters. Repeat this for each hole. Two layers were installed and the bottom of the fire bricks had some installed between the spacers. You will need an adjustable propane regulator with a gauge (acetylene regulators work), and about 5 feet of hose that is approved for propane. The rear of the cube is also insulated from the rear (bottom) of the pot with 4 inches of Kaowool cut into 13 inch diameter circles. BTW people, there is cold and hot forging. You want the burner so the nozzle is flush with the inside of the forge wall. Make a tentative plan. I have a large bag of pure fire clay, some silica sand, and some perlite. For this forge, 2 layers of 1" will be used. Includes A 0-30 PSI adjustable propane regulator with pressure gauge and 4 hose; Heavy duty stainless steel construction. MIG tip for the jet. Set an objective: What is the goal of this forge? It was slowly brushed onto the inside of the forge and outside, just make sure to cover all exposed ceramic fiber surfaces. If you are not comfortable around propane do not attempt this. What temperature can this forge get to? Line the inside of your forge Insulating the inside of your grill is important for a couple reasons. These four bolts should hold the paint can off the ground, and keep it … The bolts will hold the propane burner in place for mounting. This report covers the design, construction, and evaluation of a propane forge. The bricks were cut to fit the bottom of the tank and one brick was cut into 1 inch wide pieces as spacers to raise the floor bricks up from the bottom of the tank. Hell’s Forge Portable Propane Gas Forge. You could make a door from ceramic wood and a metal brackets. size hole I should have in the front and one in the back ..if needed. Then there is also a minimum and a maximum. Twitter. Then it was transposed to a piece of foam board or cardboard and then traced onto the ceramic board. The purpose of it is the keep as much heat within the forge as possible so Did you make this project? I thought forging was the hammering and shaping of metal. Install the propane burner into the forge opening and hold securely in place with the bolts. Asi) Wearable Steampunk Style Spider, How to Make a Nightstand From Wooden Hangers || DIY Side Table, Airtank or freon tank or propane tank or steel tube (for the container), at least 10" wide. The firebrick is a durable floor material and can be replaced if you do any amount of forge welding as the flux will eat away at the brick. A compass could be used as well. This arrangement of pipe fittings was influenced by work done by Frank Villars, David Starr, Larry Zoeller and others. The hole was marked and then cut out, I didn't have a hole saw the proper size so I drilled holes all the way around the circle and then used a Dremel with a cutting disc to cut it out. The furnace has the heavy type fire brick lining it’s interior. Put some safety glasses on and have a fire extinguisher near by. At a minimum, safety glasses or face shield, cotton long sleeves or leather, do not wear synthetic materials as if they catch on fire they will melt to your body. I have my small propane forge lined with 2 layers of 1 inch thick kaowool and then had a coat of ITC 100 refractory over that. Then the pipe nipple was tapped using a 10-32 thread tap. What will the end product be? So I'm sending just part of the questions. 3.) You cannot assume that a home made EZ burner with a poorly drilled, burred edged and crooked orrifice will perform anything like a professionaly designed and made product using precision machine tools. Then the square stock was welded to the body of the forge, again brazing could be substituted. The air tank I am using has a built in stand to keep it from falling over so this saves me a step or else I would need to add some feet. To help protect the inner lining, fill the bottom third of the forge with clay cat litter (not recycled the paper type!). Thanks! The forge body is constructed either with a steel cylinder lined with ceramic wool and coated with a protective refractory cement or a steel frame holding insulated fire bricks. The blanket in the forge compresses so the ceramic back wall was held in place by friction. Also as noted, different burners have different performance levels. This saves precious time transferring from lifting to pouring tongs. The nipple was then welded to the tank, if you don't have access to a welder, another option is the tube can be brazed to the tank. For my money, the Rex burner is worth every penny of the $200.00+ price you pay for it. on Step 12. To adjust the air gas mixture : 1. You cannot use just any size burner with any size forge OR adjust the forge outside of the operating range of the burner. There are a few choices for the refractory lining, I am using ITC-100 HT which looks like a cement/mortar, however it can with stand extremely high heats. Resistance Power: The triple burner portable propane forge entirely designed with the top-notch metal sheets. I notice that it heats up quicker and uses less fuel than a previous forge using a regular kiln refractory (don't remember the type). A front "U" bracket was fabricated from a piece of 14 gauge sheet metal, template was free handed, some holes were drilled for attaching the board. I texted a long text with questions and it disappeared. 1 year ago, It appears to be a standard 10 gallon portable air tank that can be purchased at most hardware or auto parts stores, Question The bricks were placed and then cemented together using high heat stove cement. A note about ITC-100 refractory used to coat the kaowool, it works by far better than any other cement/mortar like refractory I have used in previous forges. The burner orifice is drilled with a #57 drill bit. You did a wonderful job explaining all of the instructions. ITC-100 refractory or some other type of brush-able refractory. 2 years ago The best made forge body is only as good as the burner you install in it. Fucina Forges™ 2 Propane Burner Kit for Propane Blacksmith Forge Furnace Stainless Steel Features: Heavy duty,high efficiency propane gas burner (up to 100,000 BTU/burner) 100% 304 Polished Grade Stainless Steel made Burner with replaceable brass gas jet nozzle.Conical propane burner tube for ideal air flow and performance.Special designed flame retention type … Bracket to hold 1/8" pipe (.405" OD) in center of 1½" pipe. This little melter uses a #1 crucible (3.2 pounds of brass) - ABOVE middle. RE design of Propane Forge. When buying a commercial product the FIRST person you should ask about specifics is the manufacturer OR the seller if they are knowledgable. The liner becomes more of a heat sink much like dense firebrick and makes high temps needed for forging/forge welding much more complicated if not impossible in some instances. I realize this depends on the Forge construction/materials, the temp/humidity/weather conditions, and the amount/type of metal to be melted. To cut the ceramic wool use a sharp utility knife, it is very similar to working with house insulation. Yes, you can line a forge with soft … Coat the inside surface with ITC-100, its well worth it. Then, the propane plumbing is attached to the rear of the pot for mechanical stability and there you have it... a forge with almost no cutting required (aside from the hole for the burner and the small holes for the screws in the rear). However, I'm trying to roughly estimate the total propane usage and cost for average use. The thing that is a little different about my forges is that I cut the tank in two laterally, then put it To light the forge, use a long BBQ lighter and put the flame near the burner nozzle inside the forge. You should use two layers of the 1" ceramic blanket, because it will be easier to form to the shape inside of the forge. These small ingots would later be re-melted by me for casting small and thin brass parts from "Lost Wax" casting molds. 9" of 3/4" schedule 40 pipe threaded one end (can be half of 18" nipple), 1½" schedule 40 pipe nipple (cut in half to 1½" length), (1) 1/8" pipe to 1/4" tube compression fitting. It is a little expensive to start out unless you get an anvil of some sort for free-ish. Just a word of advice, Reil has not updated that site in over 10 years. Question To make it more portable. It is now advised that you first use, at least, a rigidizer on the Kaowool before coating with the ITC 100. The general design you choose may have more to do with available materials. I bought the kaowool and refractory from http://www.psh.ca the rest I found locally at the hardware store. ORIFICE. The forge is pretty much plug-n-play as far as use goes once the liner is installed. I built a propane forge, but instead of cutting an old propane cylinder, I used a stainless steel cooking pot: https://www.amazon.com/gp/product/B000E62GRU. Besides, the furnace layer of the propane forge has a 2-inch ceramic wool layer that is capable of resisting high-temperature up to 2600°F. The "U" bracket assembly is held in place with by the flat steel stock in the square tubing with the tapped bolts. This forge comes complete with all lining materials needed as well as a flux resistant coating for the floor to aid in protecting your forge liner from flux damage when forge welding. So, I have a propane burner I use in my forging. Use at least 2" of insulation around the chamber: The first inch or two should be Kaowool - the outer layer can be pearlite or vermiculite. Q: Can I line a forge with firebrick? I drilled enough holes below the water line to allow a sawzall blade in there. Once the refractory is dry, it needs to be cured. Registered User. Also, the integrated refractory fire bricks at the bottom can handle high-velocity firing. I tried this and it seems to work. Questions like this are based on what... 2. I highly recommend watching the video for the construction and operation of the forge. I am hoping to build a propane forge to do simple toolmaking/hobby projects initially, and down the road perhaps attempt crafting blades, axes, Damascus etc. Think about the difference before posting a question related to volume. Run the forge at a lower temperature for 15-20 minutes to let the ceramic fibers and refractory lining "set up". Thanks for the help.-smelly Coating the interior with a product like ITC-100 is expensive but pays for itself by making the liner much more resistant to flux and making it more efficient. I have used a steel pipe I found at the scrap yard that worked very well. This burner is very large and can damage you and property. Maybe an hour to get it to casting temp. A piece of ceramic board was cut that was larger than the opening of the forge but the size of the opening is up to you as it needs to be big enough in my case to have tongs fit in and out. You want to keep these fibers out of your lungs! I was wondering how others have cast theirs, what the mixture and materials were? I did later cut a rectangular hole in the lid of the pot to cover the front - but this is not really necessary. 70% zircon, 30% kaolin by weight from the thread linked. Thread a second nut onto the leg and tighten so that the bolt is secured to the can. Which Metal Element names were you able to effectively melt in a Ceramic Cruicible? on Step 6. LPG blue flame colour burns 20°C higher than a natural gas blue flame colour. You have been warned, I take no responsibility if something goes wrong.Always wear safety equipment when lighting and working on the burner. The ceramic blanket and board needs to be stabilized so fibers do not become airborne when the forge is in operation. Don't operate the forge at full power until the refractory is cured. I can post a pic if need be. I have access to a welder so I was able to weld some parts together for this forge but if you don't have access or know how to weld, an option is you can braze the parts together or be creative and bolt things together. Facebook. I don't have answers for your other questions. Take the goals and decide on these factors: Number of burners, size of forge, amount of usage,... 3. Important! One of the great things about this flux is that it will not drip or foam up during welding like most fluxes on the market, therefore, avoiding damage to the forge lining. Propane forge lining. If following a video of a DIY building project is the best way for you to create, … See pic. A 1 … I work at a steel mill and have collected some scrap materials from when maintenance has been done to our hydrogen furnace, and after watching this, I'm more encouraged to get started, Great job, and I appreciate you posting it. Can a ceramic front door or gate be safely and effectively added to help increase internal temperatures more quickly while reducing heat loss? They are not called a furnace or an oven, those are different units used for different processes. 2.) As with the positioning of the gas … Along with a couple of coats of refectory cement. The circumference of the forge was measured and then the blanket was cut to size. About: http://www.youtube.com/c/AndrewWorkshop. I am 100% going to make something like this. Here is a list of the main tools used, some may not be listed. Insert one bolt into the hole you drilled into the paint can. When he put the info out there the acceptable coating for Kaowool to reduce the possibility of airborne ceramic particulate was just the ITC 100, it has since been challenged and updated. On the body of the forge a piece of 1"x1" square tubing had bolt holes tapped so 10-32 bolts would could be installed. Reply The interior heat chamber is 18” long 6” wide and 4” high. When building a forge (my way) using a 20 pound propane bottle the volume of the fire box is 583.4 cubic inches and with a typical Freon bottle it is about 259.2. Once the refractory is dry, it needs to be cured. Welcome aboard Pete, glad to have you. That stuff is pretty bad for you. I’ve always wanted to build a decent forge and I finally got around to it. under the floor will reduce the volume of your forge and bring it's temp up. This will catch any flux before it eats the lining and protect agaist dropped items. It was fastened to the "U" bracket using coarse screws. Answer Steel tube or iron pipe fitting sized for the propane burner, Piece of 14 gauge or similar thickness sheet steel. Share it with us! To figure out what min. You will need about ½pt. But you can use anything that is similar, such as a used Freon or propane tank. The opening for the propane burner was cut open as well. I have a few Questions. In this Instructable I show you how to make a high efficiency propane forge. We no longer recommend building melters this way. Parado-Asi (Pardox. & Max. Once I got a six-inch section cut out, I emptied it out, and lit a large charcoal fire on the inside and outside of it. Rex Price can tell you exactly what his burners are designed to do and I believe provides technical infromation with the burner and on his web site. Preparation for first burn. Don't operate the forge at full power until the refractory is cured. 1 year ago It is better to cut it a bit larger so you can trim it down. The blanket can be purchased in different thicknesses, I recommend getting 1" thick rather than thicker ones as it is easier to work with. Propane Forge is inevitable product for a Blacksmith, Hobbyist, Jewelers & Knife makers. Ideal Propane Forge Dimensions for Knifemaking. 1/4" NPT to LH fuel welding hose adaptor. For small melters the entire top and body can lift off and the crucible picked up directly with pouring tongs. Crank up the temperature of the propane burner and observe to make sure everything is working properly. Do you have any idea what to use to stabilize the kaowood. 4.) A utility knife was used to cut the board. 1 year ago The back wall is the exhaust port and also can allow for longer pieces of metal to be worked in the forge. English has developed over the last 1400 years, nevertheless that's plenty long enough to make your point. We repeatedly have folks give dimensions for an area NOT a volume when asking questions. The ITC 100 alone is no longer suggested or recommended for eliminating airborne ceramic particulate from the wool. Is your Propane Forge recommended to be used only on concrete bricks, or a concrete floor, or in a sandy "pit" ? No size fits all purposes. Q. I am wanting to line the inside of my 10" pipe forge or propane can forge with 2 inches of ceramic blanket lining, should I use the 1 layer of the 2" or 2 layers of the 1"? Keep that in mind at all times, and your mind will be in the right place. When propane if used properly is a very safe fuel but bad things can still happen. I am building a propane forge and would like to use a castable lining rather than ceramic wool. Yeah I have wondered that myself, I have done some research on this and have not been able to find any consensus. Were did you get your ceramic board insulation? Propane Forge Build/DIY – Using a Gas Bottle and a Kit! Here is an Instructable for building a propane burner or Google Ron Reil propane burner: https://www.instructables.com/id/How-to-Build-a-Propane-Forge-Burner/. Let the refractory dry before operating the forge. Paint the forge with high heat paint, especially the places where there is exposed metal. KnuKnapper. Important Warning: Do not attempt this Instructable if you do not have experience with propane and how it burns. It is made from the ceramic board. Run the forge at a lower temperature for 15-20 minutes to let the ceramic fibers and refractory lining "set up". To mount the burner a pipe nipple was tapped and welded to the forge bottom. The forge is ready to be used. -The best durability of any forge lining material.-Once heated, you can turn down the fuel/psi and the forge will maintain its heat ... A propane forge is nothing more than a controlled explosion. and yup no idea why they use the term forge. It needs to be mixed with water so it becomes like a slurry that can be applied with a paint brush. But best to use it on non flammable area and outside. True there is cold and hot forging, but you will never get the strength that hot forging produces in steel. I welded some aluminum stock for feet and a handle on the top. Here are some pics of the forge with measurements included for reference. 4 years ago. Turn on the propane slowly and the forge should ignite. Making Your Plan 1. A propane burner will be needed to power the forge, see two different designs here: For the forge body is a portable air tank. I would suggest you do a little historical research on the subject if you have an actual interest in it. For any given burner there is an optimum forge volume. The bottom of the forge needs to be lined with fire brick. By. The purpose for building this propane forge was to replace an old charcoal forge in order to ... Another article described the need for fiber lining inside of the forge (Zoeller, 2012). Thread one nut on each of the four bolts about 1/2 inch. Actual the hearth has been called a forge for atleast a couple thousand years, the act of making something is called forging. The forge is ready to be used. WhatsApp. Not sure but I think a full 20lbs tank of propane would last around 5-6 hours of constant use. Question So I only have that long to forge. I've been wanting to make a forge for various metals for quite a while, and I'll definitely be referring back to this very clear and detailed instructable when I start mine. Turn on the propane slowly and the forge should ignite. Hope that helps. Sia Magazin - December 11, 2018. Did you place the metals to be melted inside the Propane Forge when it is "cold" or else after the Propane is "hot" and at high temperature? The lift off lid and vertical crucible lift requiring special tongs (above) are both remnants of the heavy brick lined furnace days. But it's so amazingly rewarding when you get something done. The written steps follow. ceramic cruicible to make small 260 Brass ingots. I have a whole aluminum beer cage. I'm gonna try this. The second is a blower driven box forge with a radically different construction. The key material for the forge and insulation is the ceramic blanket and board, it goes by brand names such as Kaowool. A 5 gallon (BBQ size) propane tank fits in the forge stand. I used a pot that was a good size to trace out the size of the opening. Remove the burner from the forge to avoid heating up. As a Blacksmith Forge The propane forges described are both suitable for blacksmithing work. 292. This forge can be used for knife making, blacksmithing, glass making or anything else you can think of that requires heating up stuff to a really hot temperature. YouTube Video. This is so so cool. I have made my own atmospheric burners and also used 3 different commercial offerings. I am in the process of building a propane forge primarily for damascus blade making (up to 14" overall) There are several excellent designs available on the net but a little knowledge can be confusing if not dangerous! Leave the forge at low power. First, adding insulation will allow your grill to get hotter, bringing it up to the critical temperature faster, thus making it more efficient and allowing you to … The consistency should be like thin pancake batter. There are a few things I’m not familiar enough with to eyeball though. What size tank is this? There IS an area to consider and that is the minimum vent size for the forge relative to the burner. 5.) I don't know how the furnace, or oven, has taken on the name as "forge" so much. Pinterest. A. KnuKnapper. I'll leave it to your imagination to add the feet to what ever tank or tube you use, suggestions are some large bolts or weld on some tubing. The placement of the tube was at the top of the forge and placed on an angle. It melts a full 3 pound crucible in about 5 minutes or less once the furnace and crucible are hot (about 10 to 15 minutes). Do it!!! The major portion of the flame should be an electric blue color with only a hint of yellow or orange at its tip. Let’s start with this brilliant portable propane gas … The first is the atmospheric pipe forge described in the dvd. Big, big thumbs up. Also never assume we know the details of someone else's plans. 1.) Home › Products › Propane tank forge lining kit Products Sort by Featured Best Selling Alphabetically, A-Z Alphabetically, Z-A Price, low to high Price, high to low Date, new to … Today, using light weight refractories, forge and furnace design can and SHOULD be different. The board is a rigid ceramic board and will be used for the opening and back wall of the forge, thickness is 1". Is the a formula for the inside diameter and length. Copper would be fine, to a point so would bronze but not steel. If you have the extra money spend it on the ITC-100. Wow. Leave the forge at low power. If you can find a flange for fencing the proper size, it could be bolted to the tank.
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