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Dealing with Scale

Oxidation occurs during the heating process, as air contacts the steel. This process creates what blacksmiths call scale or slag. In a properly built coal fire, positioning of the steel and control of the air blast helps to reduce the build up of scale on the work piece. Scale that is left on the steel during forging forces the scale into the steel, leaving a mark on the piece. The greater the scale build up, the less attractive the finished piece.

The Forgemaster TM forge eliminates the need for the blacksmith to constantly tend the fire as with coal. This allows for greater production time in a much cleaner environment. In the heating chamber of the Forgemaster TM forge, the air blast is in direct contact with the steel. The atmosphere that enables greater production and ease of work can also increase the amount of scale. A few simple steps will keep your work looking clean and crisp.

1) Only heat what you can easily work. Don’t overload the forge with work pieces. The heating ability of the Forgemaster TM is exceptional, and most experienced blacksmiths find that they can only keep up with a couple of pieces at a time. A piece of steel left in a gas forge heating chamber too long will develop a larger amount of scale.

2) Use the lowest temperature possible to reach forging heat and keep you busy is the ideal. Set your Forgemaster TM pressure regulator at as low a pressure as possible to keep up with the work you are doing. When working on small stock use low pressure (5 or so psi ). Larger stock may require up to 10-12 psi.

3) Work an edge first. Hammering on the flat face will result in hammering scale into the work. Light hammering on an edge will cause the scale to break lose and fall off of the work.

4) Brush the scale off. If hammering an edge is not possible, bending the steel will also loosen the scale. If neither of these techniques is practical for the piece, use a large bristle wire brush (Butcher Block brush) to remove scale prior to forging.

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Tips

Relining a Forge

If you expect to get the best performance out of your Forgemaster TM you will need to pay attention to the liner. Lining walls that are worn to half of their original thickness will allow a greater heat loss, and will take longer to reach forging temperature. You know it’s time to reline the forge when:

• The lining material is worn greater than half the original thinkness of 2″.
• Moisture has been allowed to reach the ceramic lining material.
• The hearth brick is badly deterioated due to wear and vibration.
• The heart brick separates from the clip and loosens from the housing.

“Why should you reline your forge?”

• A new liner promotes longer forge life.
• A new liner prevents warping and damage to the steel housing.
• A new liner promotes better fuel consumption efficiency.
• A new liner promotes higher constant heat temperatures.

The May/June 1999 issue of the American Farriers Journal has a “tear out” page that will assist you in relining your forge. This special section was sponsored by Forgemaster TM as a courtesy to our customers. You will also want to check out our full page add in the AFJ Supplies and Services issue.

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Tips

Apply Drill Tek






Step #1

Break the stick of drill tek into small (3/4″) pieces. The easiest method is shown below.



Step #2

After setting out all of the pieces of drill tek, and equipment, heat both heels of the horseshoe to a bright orange heat.



Step #3

Remove the shoe from the forge when it reaches a bright orange heat, and quickly brush the scale (don’t spend too much time with this or you will lose your heat). As soon as you have quickly brushed the scale, sprinkle some brazing flux onto the heels where you want to apply the drill tek. Then (using the pliers) place one piece of drill tek on each heel and return the shoe to the forge. It will not take long for the matrix of the drill tek to liquify. It is wise to remain close by and ready to remove the shoe AS SOON as the drill tek becomes shinney be ready, the brass will soon begins to flow.



Step #4

The moment the drill tek begins to flow, remove the shoe from the forge. Move to the anvil and drag the foot surface side of the shoe across a sharp edge of the anvil to remove any brass that flowed to the back side of the shoe. Then position the drill tek by using your hammer to gently move the particles while the brass is still in a liquid state. DO NOT QUENCH the horseshoe, allow it to air cool.



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Tips

Bundle Welding

One of the most versatile welds for the blacksmith is a bundle weld. By welding a collection of similar size pieces together you can create a variety of ornamental items. In this technique we will show the basic process of the bundle weld. Your imaginative application of this technique can add excitement to many of projects.

Bundle the desired number of pieces together. To hold the bundle together while heating and forging, wrap the pieces with wire or……………

An effective means of holding the pieces together during the forging process is to use an adjustable hose clamp.

After you have the bundle secured, place the end into the heating chamber of the Forgemaster TM. The heat chamber should be at welding temperature.

When the bundle has reached welding temperature, remove it and quickly brush off the scale and…….

apply welding flux. Both brushing and application of flux should be done quickly in order to retain heat. Return the bundle to the fire as soon a possible.

When the bundle again reaches welding temperature take the bundle to the anvil and with light rapid hammer blows forge the pieces together.

The completed bundle weld has been twisted and is ready for your application.

This bundle weld has been applied twisted with the ends spread in a “sun burst” pattern for a garden trellis. (click on the image for larger view)

The completed trellis.
(click on the image to for larger view)

Forgemaster On line shopping

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Tips

Forging a Natural Looking Leaf

Ornamental ironwork requires some practice to develop the necessary skills. This project will help develop several forging skills, and provide attractive leaves.
Select a 18″ length of 3/8″ round steel. You can use a shorter piece, but you will need to hold the piece in a pair of bolt tongs.

1) The first step is to forge the end to a point. At the edge of the anvil, angle the work piece and the hammer blows to effect a tapered end on the steel.

2) Now “neck down” a portion about 3/4″ behind the end of the steel. This is accomplished by using the edge of the anvil and the edge of the hammer to “fuller” the steel.

3) Next flatten and draw to the shape you wish. By using a cross pein hammer, you will move the steel faster and in the direction you want.

4) Fold the leaf in half, to forge the center vein in the leaf. Use the step of the anvil, and a cross pein hammer to begin the fold. Finish the fold on the face of the anvil. Hammer the crease area tightly to form the center vein of the leaf.

5) Heat the folded leaf, and begin to open the fold with a flat screw driver. Once the initial opening is made forge the leaf open using the edge of the anvil. Continue to forge the curls and shape that you desire.

6) Add the cross veining with a cross pein hammer…

7) Finish the leaf with a strong wire brush. For a bronze finish use a copper or brass brush.

Leaves forged in this manner may be welded together to enhance any ornamental project (see Forge Welding Tip).

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Tips

Drain the Lines

When you are ready to shut the forge down, the following steps will help to increase the life of your fuel lines and regulator.

1) While the forge is running, close the tank valve.
2) Allow all of the propane to burn out of the fuel line.
3) After all of the propane has been consumed by the forge burners, turn the regulator pressure screw counter clockwise (to reduce pressure).
4) Finally close the forge fuel valve.

Following these steps will clear all propane vapor from the fuel lines and regulator. If you allow propane to remain in the fuel lines and regulator it will reduce the useful life of the fuel lines, because the propane vapor solidifies into a waxy substance that will clog the hoses, regulator and valves of your forge. This simple proceed ure will also prepare the equipment for your next job. When you next light the forge, you will open the tank valve first, then slowly increase the pressure at the regulator to the desired psi, and finally open the forge fuel valve for ignition.

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Tips

Lighting the Forge

Lighting the Forgemaster TM

A general understanding of the properties of propane and a venturi will make lighting your forge a simple thing. It is important to know that propane has a relatively small ignition envelope. In order for propane to ignite it must be mixed with air in a ratio of 2% to 10% propane vapor and 90% to 98% air. Mixtures that vary from these limits will make ignition very difficult or impossible.

When the forge is cold, the Forgemaster TM venturi burner will draw air at a tremendous rate. Because of the draw of a cold forge, the fuel-air mixture will normally be outside the ignition limits of propane vapor. Forgemaster TM forges have an air limiter at the rear of one of the burners to restrict the amount of air that can be drawn into the venturi burner. Keep these three pieces of information in mind when you light the forge, and follow these lighting procedures:

1) If your Forgemaster TM model is equipped with a front door, open the door fully during lighting, as shown below.

2) Make certain that the brass fuel control valve on the forge is turned OFF.
3) Open the valve on your propane tank.
4) Set the regulator gauge to 10 psi (15 psi for the E-1 model). To set the regulator, slowly turn the center knob of the regulator clockwise until the needle on the gauge points to the number 10.
5) At this point you should always test the tank, regulator, hose and valve for any loose fitting and propane leaks. This is easily done with a commercial gas leak checking liquid. You can make a sudsy liquid by placing a small amount of liquid dish detergent in a jar with some water and then apply the sudsy solution to every fitting and joint which is under propane pressure. If the solution continues to form bubbles you have a propane leak, and should shut the tank valve off and repair the leak BEFORE proceeding to light the forge. Even a small leak should be fixed immediately. When you are certain that there are no leaks in your forge system continue with step 6.
6) Close the air limiter at the back of the venturi burner. (Some older models of Forgemaster TM are not equipped with the air limiter, but you can purchase one from you dealer). The purpose of an air limiter is to limit the amount of air that is drawn into the venturi burner. If you have an older model and have difficulty lighting it, you can make a temporary limiter out of sheet metal and place it over the air intake at the rear of the venturi burner during lighting. Make sure that you have a fairly tight a fit over the venturi burner.
The photo below shows the air limiter in the proper position for lighting the forge.

After the forge is properly lit you should open the air limiter as shown below.

1) Be sure to open the front door if your forge is equipped with one.
2) Stand to the side of the forge, away from the front opening. Open the brass fuel control valve at least one full revolution. Wait 2 seconds and then…
3) Push the red button on the spark ignitor. You should not need to push the button more than 2 times if you have followed these steps.
4) After the forge is properly lit you may close the front door if you forge is equipped with one, and begin forging.

When the forge is burning properly you will a flame in the heating chamber similar to either of those shown in the photo below. You will not be able to see the flames in bright sunlight, and you should NEVER get close to the front of the forge. Obviously forges are hot.

If the gas ignites prematurely, it will burn in the venturi burner. This will produce a loud, gurgling sound, and a blue flame can be seen inside the venturi burner. When viewing this from behind the forge, look into the venturi (from about 18″ away). A forge running in this manner will not produce enough heat for forging steel. It will look like this –

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