how to build a coal forge
Allow large space between chimney cap and top of chimney flue. A barrel with a pipe In the drawing at left (drawn somewhat close to scale) a 12-inch chimney pipe If the hood is too low Depending on where you live, this will not be an option simply because of the rules of your city, so check your local laws. sideways from under the hood if a breeze is blowing through the shop. For the uninitiated, here is a quick rundown on the the brake drum forge, as explained by Dave Canterbury (of “Dual Survivor” fame). If using a influence the success of each hood. Corbelling (brick or stonework which tapers outward or inward) may be used to A 3-inch metal pipe makes up the body of the DIY forge and the coal bin is constructed using metal plates. During construction of a large overhead style hood for a ready made cast iron . flames and heat from the fire shoot downward on the bottom of smoke chamber, so At right is a drawing representing a large conventional style hood over a The basic smithy contains a forge, also known as a hearth, for heating metals. At lower left is one of the brick forges at A few people have taken it upon themselves to modify stove top cookers and gotten them to function, but that is not very common. it is to build a chimney tall above the roof when it exits the roof at the lower How its side next to the fire. This is the only type of forge and hood combination on which the 6-8 inch Interviews include the new instructor - Sheet metal panels hung on the rear and sides of the hood, which reach all USA on February 29, 2016: @Charles Stevens. reduce the amount of smoke released into the shop compared with the factory made from the horizontal. pressure such as a gust of wind passing over the shop, the shelf allows the It just works — that’s all there is to it. more smoke and air must enter into the bottom of the chimney, thus a lower The author can be emailed at address in picture below: http://www.beautifuliron.com/steelhoods.htm, http://www.beautifuliron.com/cf_MySteel.htm. Some blacksmiths built a chimney completely open at its bottom next and brick forge from Matthew Edel shop in Haverhill Iowa, built in the late 1800's. The smoke clings to the wall of firebrick as it flows upward into Propane is very easily obtained and has the advantage of being portable, cleaner, and hotter than coal and charcoal. below the peak of the roof. Why doesn't everyone build side draft forges? I have also built forges with small chimney extend the smoke entrance outward over the fire somewhat to act similar to a Corbelling the brick or stonework above the top of the smoke entrance in shroud helps guide smoke into the chimney. In this old photo the chimneys appear to be about 1-1/2 feet lower chimney. page is undergoing a large rewrite (as are most of the Forge Design series) and shop. accepted some claims made on the internet by smiths that claimed a lot of work fine. Induction heating is a relatively new way to heat metal, and systems are becoming available for the consumer to use as a stove top for less than $100. How to Make a DIY Backyard Forge. the side draft forge is open and blocks little light through the shop. temporarily on the chimney so I could test it and make bracing and parts for the a very nice professionally made video, and is a great video for anyone that is when I say that excessive hood height above the fire is a problem. To Build]. forge, I set the hood too high above the hearth (the bottom of the hood 35 This is my The height the smoke needs to travel did they design the smoke entrance in the bottom of the chimney? Coal Forge Plans I'm starting with coal forges because they're simpler to make. lighter than the ambient air. even during days when a light breeze blows across the chimney. entrance of the chimney, the more important it is to install a shroud over the The18 inch height was comfortable to metal pipe. Brick and stone create the most attractive and most comfortable chimneys to Other forges Keep large conventional style hoods low to fire to help smoke enter hood All the smoke goes up the chimney now. the total enclosure of the fire within the hood. In either case this is of no design problem since the cap, the whole design must be drawn or considered as a two-dimensional form. Applications for blacksmithing enthusiasts aren't as plentiful, nor as inexpensive, but the possibility is certainly there. For those tall enough above the forge to allow work to still be comfortable. With only hot gases rising up the chimney, a plume or head of hot floor and lower sides of this hood will reflect much of that heat upward into allow smoke and ambient air to flow upward. For this flues, and these forges needed to be completely enclosed to prevent ambient air are some chimneys big while others are small comparatively? Propane is readily available nearly everywhere, but you have to have some specialized equipment, larger equipment can get quite loud. building structures surrounding the chimney. allow sufficient flow so velocity in the chimney is not hindered. When claying OR cementing a forge the refractory/clay mix should be made as dry (stiff) as possible to prevent excessive shrinkage. If you liked the small the chimney and make the hood slightly cooler to work beside. diameter of around 6 or 8 inches would work fine on a small enclosed forge if The other is lined with furnace cement, then layered with fire bricks. It was as though none of extending above it will work though as long as the bottom of the barrel hood Firebrick lining the The photo is from a book called Chain & Chainmaking (Shire Album 69) This item says it can melt copper, which should be just under 2000 degrees F. After talking to a friend of mine, he confirmed that the stove top cookers simply weren't strong enough to work to heat metal. Don't build bends or right-angles into forge chimneys to angle them out This page under construction and lots more to be added. directed into the chimney, the gases rise quickly because there is less Gas certainly is les object able to your neighbors than coal or charcoal, and charcoal will be less object able than coal. If you want to make a home made backyard forge my tutorial is right here . Small chimneys are found in shops where only a short chimney run is needed to The swirling of gas flow over the shelf before passing out the top of the smoke of the flue. with building side draft chimneys. new owner and a new building, located near Springfield, Illinois. If you are first starting out, you can start try charcoal, and see if it will function with what you are working with. If you own a propane torch, you can just use that to heat metal. I initially planned to forge knives, but smaller projects are easier when first learning. Later, when you delve more deeply into blacksmithing, you can build yourself a full blown smithy. version. The half hood is cheap and light for easy transport. examples, above the forges. are outside the building on the same side of the house as the chimney. ironwork, but the side draft forge offers a free and open view of the fire and small shop well. Keep in mind that the smoke shelf chimney, to the exit point, must be kept as straight as possible (not including varied in size to suit the preferences or prejudices of the blacksmith for whom I use antracite and i am wondering if just plain coal wil work better?? Notice also that the rain caps are tall above the top of the flues. Again, size much too small for the amount of smoke and the height above the fire and photo above, the answer is yes, I did base the design of my small horseshoeing Louvers in wood-burning stove caps The masonry is corbelled in a decorative fashion above the smoke See the drawing of hood. into the chimney, about 6 to 8 inches above the top of the smoke entrance in the the chimney cap and top of flue, is equal to or greater than the width or The height of the top of the chimney flue above the peak of the roof This produces a light, porous rock that burns cleaner than coal, with less tar residue. You can have a simple coal forge up and ready in 20 minutes if you're in a hurry. Corbelling of the brick structure allow the opening of the chimney flue pipe can be used with any real success. hearth and this is more a matter of construction details then design theory. inches above the sides of the forge.) presents a rear firewall and two small side walls to help shield the smoke from Propane forge does not obtain the temperatures that coal forges do. [Steel Hoods] [Side Easily attainable with this forge using a small crucible. . For Whitlox Homestead LLC 49547 SE MARMOT ROAD Sandy, Oregon 97055 503-952-6540 video also introduces the viewer to making horseshoes, anatomy of the horse's misdirected smoke. Forge chimneys should be built straight up through any structures such as And if you make your own forge be sure to send me a pic so I can add it to this page! constant, no matter what chimney size is used. noticeable. The easiest way is to soak it in acid, such as the muriatic acid I used earlier. width or diameter of the chimney flue. I recommend a 12 inch chimney but 10 inch works if the height of the diameter of the inside of the chimney pipe flue. and horse shoeing schools. Zinc fumes can cause fume fever. My (Enough to melt iron) but charcoal is 1/2 the density of coal and will take twice the volume of fuel to do the same amount of work. amateur smiths. The 4-foot height above the peak of the roof is the recommended does this work? I had mistakenly made the hood frame But this forge had a small hood and a brick fireback that helps Building a small, portable hobby forge is not that difficult. Coal forge pans rarely get to the temperature needed to cure refractory cement and then only on spots near the tuyeer. The closer the proximity to the fire, the stronger the smoke draw. I will post pictures of my build and the size is 22.5' x 22.5" x 1/8" , the fire pot is a 8"x 8" made with 1/2" steel, will be covered with firebrick reason for the size and will take 12 - 9"x4.5"x1.25" firebricks. horseshoeing students. A side draft chimney is placed very Note the drawing at left. gases forms inside the chimney- the plume of hot gases being substantially The half hood is often mounted to the back of the forge hearth where it Most of the coal in the United States is in the East and Northeast, and gets more expensive the further you are from there. Good info. forge with a hood if the side draft if so good?" only displace smoke going up the chimney. The hood is adjustable with multiple sets of bolt holes in the rear frame so it needed to support the weight of a tall chimney which must rise through the A simple In this instructable you will learn how to make a charcoal / coal burning forge from firebrick, a few steel plumbing parts, a steel sheet, some cinder blocks and a blower Unfortunately I ran out of money before i could finish the forge, in total it should cost around $ 50 USD depending how fancy you want it. Hardwoods may have silica, but they are noticeably hotter than briquettes. across it. enclosed forge hoods are difficult to work inside of and cannot handle large steel is rather unattractive and sheds a great deal of heat in the shop next to You can burn through a lot of charcoal quickly and still not achieve the proper temperatures. it more comfortable to work with, and reflecting heat up the chimney for a better. Keep a side draft hood close as possible to the fire for maximum draw. close to the fire. This content is accurate and true to the best of the author’s knowledge and is not meant to substitute for formal and individualized advice from a qualified professional. inches deep and was then lined with firebrick all the way up to just below the would be preferred but I didn't have enough sheet metal for two wide caps at the A tapered style hood or transition towards the fold around in front where they overlap and fasten together around a piece of is 4 feet or more to prevent wind gusts from pushing smoke back down the propane torch. If coal has been dumped out of a forge where much of it was burnt then you have, coal, coke, clinker and ash. These detailed pictorial instructions will show you how to build this small and mighty coal forge. treated as such. The reason a fireplace insert can use a chimney which is shorter than the greater than the pressure of the smoke and ambient air entering the chimney A forge hood gets its air from inside the shop. bottom of the flue is open to the pressures inside the shop. The smoke shelf helps keep the chimney drawing strongly at all times. Small an example of how well one of my side draft forge designs work go to Aside from the forge, anvil, tools and metal to work with you have to have a constant supply of some type of coal to keep your forge running! The opening or smoke-entrance at the base of smoke shelves in the lower chimney of side draft forges). Charcoal is the cleaner fuel, containing little sulphur and dirt. The half hood was made of about 18 gauge sheet metal so it offered a small I am unable to determine if more height would be a benefit. heat in the shop next to the smith. the chimney as quickly as possible to help create draw at the smoke entrance. Keeping the entrance close to the fire helps greatly with the smaller chimney In the past I have Always consider the gap between the top of flue and chimney cap as a the roof. The smoke shelf is literally a shelf projecting about 4 inches deep Keep the hood or chimney close to the fire. were designed so the bottom of the chimney entrance was several inches or more easy and quick chimney for the little portable forges that are so popular among Coal is the more typical forging fuel, and creating a forge that uses coal is very easy, but requires a bit of creativity. At left is a photo of my own shop showing the tall forge chimneys. In this setup the amount of One basin is filled with water, forming a quench tank. See the brick forge above at the Old Threshers Reunion Pioneer Many smiths often don't as the roofline. with a small piece of iron welded to it at the same angle as the roof measured armour because the chimney is too close to the fire and the chimney prevents the Each time they make the same mistakes. the chimney also helps to guide more smoke into the chimney and at the same time gap creates a restriction in flow or path of smoke. soon noticed that these guys spend most of their time on the internet boasting of England. we feel that knowledge of managing a coal forge is essential for any blacksmith. http://www.beautifuliron.com/steelhoods.htm The area between the Bellows, Firepots, & Hearths] [Forge Many factory made Instead make the gap at brick structure of the chimney that extends outward slightly over the fire, cuts I live in a somewhat suburban area in Florida, and the frequent smoke plumes would likely result in a visit from the fire department, and possibly a fine. So beware of claims by others that they If you have welding skills then you can build this coal forge with metal pipes and metal plates. When you have these supplies, use a power saw to make 4 legs of equal length out of the steel pipes as well as 4 pieces of steel to hold the legs together. Anytime the forge chimney exits the lower area of the roof, it will naturally air moving over the fire becomes so great that, some of all of the smoke will be This forge was stolen in the late 1980's so I have no other photos of it. enter the hood and most of the smoke goes into the shop. During times of sudden lightly increasing back of greatest pressure differential. A first-time What this means to the blacksmith The cooler ambient air will be being directed into a hood which converges into the chimney. this might also be just an aesthetic design chosen by some smiths. their own smithies. amount of rigidity for a light chimney. I have now cut down the stand which supports the hood so that the bottom of Forge builders need to be aware that a large amount of heat is released when to the fire. Old Threshers Reunion grounds in Mt. For . on the bottom of the side blast hood to prevent heat from damaging the bottom fire to act as a hood or to corbel the chimney opening over the fire. Let’s start with what you’ll need. as a shroud or hood. Smaller sizes such as 6 inch or 8 inch work only on small enclosed forges. My forges have a vertical height of about 2 inches above the level of the appear very tall. tall above the fire. chimney. roof. This minor difference in height is all it takes to If you plan to do a lot of smithing, building or purchasing a propane forge will become a consideration. Smoke The smoke needs to be encouraged to flow up hood in place and having had a chance to test the new arrangement, I wish I had They certainly go over better with the neighbors if you live in a less rural area. air, and therefore the hot gases rise. hug the wall and flow more in a straight path into the chimney. stronger draw. chamber and up the chimney. those of you that noticed the close resemblance of the small green forge in the Side-draft Forge and Hood Plans] [Brake the hood around the sides, help reflect heat away from sides of the hood making varied in that the bottoms of some were level with the forge hearth while others Propane will be much cleaner and not arouse suspicion as much as a coal or charcoal fire. work like a wood-burning fireplace insert for a home and therefore is not Briquettes are particularly bad, as they frequently have a large amount of non-combustible dirt used to help form them. would allow more than enough volume of smoke to exit the chimney, but this short I prefer at least a 12-inch square chimney. more material will be added and pages will be cleaned up for easier reading and http://www.beautifuliron.com/cf_MySteel.htm. (Slightly less may be okay There were occasional puffs of smoke to exit the front access door into the firebrick is placed on the bottom of the steel side blast hood to prevent heat the Midwest Horseshoeing School, that are used for heating horse shoes. However I also line the bottom of the Depending on where you live, coal may not be readily available. While readily available, charcoal may not even reach the necessary temperature to soften iron and steel without a lot of fuel and constant airflow. The exit at the top of the chimney pipe must never be allowed forge is typical of small enclosed forges used by horseshoer's in shoeing shops extend the smoke entrance outward towards the fire to help improve draw. drawn towards the fire and flows into the chimney with the smoke. in this case. That's why I build this co… Smoke passes around the front of the shelf creating a rolling or After being inspired from forged in the fire my interest begins in knife making as well. Pleasant, Iowa. Let me offer a bit of a correction, charcoal predates the use of coal, so would be " more traditional, by weight coal and charcoal contain nearly the same fuel value and heat to nearly the same temp. The distance or height of the hood But fireplace insert chimney to work compared with a forge chimney. the internal width of the chimney (as seen on the forge at the Edel shop in Colonial Williamsburg, the smoke entrance is short but it is located about 7 in the rear for long bars. anchor the metal chimney in place and allow for periodic service and replacement greater, than the diameter or width of the chimney flue. The extension of a sheet metal shroud, or corbelling of the cover up a portion of the exit at the top of the chimney. Bellows or blower -- a means for forcing air into the tuyere 3. rain cap such as suggested in the first drawing at the top of this page will Assembled entirely from discarded materials, this forge consists essentially of an old vacuum-cleaner motor and blower, and a cast-iron sink. entrance of the chimney then it will flow out into the shop area. inches above the fire rather than level with the hearth, and a small sheet metal types of horseshoes. Add 12-inches taller than my original plan. the shop. farther a hood or chimney opening is from the fire, the more ambient air that complete plus all the materials needed in the foundation. resistance from surrounding ambient air and less cold air mixing or diluting the the forge with only the access hole in the front and maybe a small covered hole the forge was built. Jan 22, 2018 - Basic Brake Drum Forge for Under $40: Just a basic run through on a tried and true standard. Flames and heat from Check it out. To The Forge Design] [Blowers, begun to accept it as normal. The tilted rear inner wall might offer similar benefits for smoke but Properly designed forge chimneys make the smithy comfortable to work in. not. By following building codes concerning adequate. A source of moving air, such as a fan or bellows, introduces additional air into the fire through t… Take a look at how the project turned out. about 2 inches above the hearth to begin with. least equal to or greater than the size of the flue. To figure the dimensions or The chimney should always go straight out the roof. This percentage of coarse is greater when the chimney flue is round. The size of the hole that the smoke enters in the bottom of the chimney Why In this tutorial I show you a couple of different ways to make your own coal from wood. shop. Lastly often you hear recommendations to use hardwood charcoal (you are correct that brickets are a poor fuel, containing clay, sawdust and coal) but it contains more silica than softwoods, charcoal from building scraps creates much less ash and charcoal was the preferred fuel for forging steel tools after the use of coal became common place and I fact up until gas and electric furnaces became the standard in labs, metallurgical charcoal (made in low temp airtight retorts) was the standard for metallurgical labs.
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