When Is Wrought Iron Not Wrought Iron?

August 3, 2018 by Jenny List 70 Comments

I grew up with a blacksmith for a parent, and thus almost every metalworking processes seems entirely normal to have as part of everyday life throughout my childhood. There seemed to be nothing we owned that couldn’t be either made or repaired with the application of a bit of welded steel. Children of blacksmiths grow up with a set of innate heavy hardware hacker or maker skills that few other young people acquire at that age. You know almost from birth that you should always look away from the arc when dad is welding, and you also probably have a couple of dictionary definitions ready to roll off the tongue.

The first is easy enough, farrier. A farrier makes and fits horseshoes. Some blacksmiths are farriers, many aren’t. Sorry, my dad made architectural ironwork for upmarket houses in London when he wasn’t making improvised toys for me and my sisters, he didn’t shoe horses. Next question.

The second is a bit surprising. Wrought iron. My dad didn’t make wrought iron.

But… Hang on, you say, don’t blacksmiths make wrought iron? At which point the floodgates open if you are talking to a blacksmith, and you receive the Wrought Iron Lecture.

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Impressive Custom Built Blacksmith’s Forge

August 3, 2016 by Gerrit Coetzee 28 Comments

[EssentialCraftsman] is relatively new to YouTube, but he’s already put out some impressive videos. We really enjoyed an episode dedicated to a fixture in his shop, his large custom blacksmith’s forge.

The forge is a custom cast vault of refractory that sits on a platter of fire bricks suspended on a heavy-duty rotating frame. Two forced air natural gas burner provide the heat. The frame is plasma CNC cut steel welded together.

A lot of technical challenges had to be solved. How does one hold a couple hundred pound piece of refractory in such a way that it can be lifted, especially when any steel parts exposed to the heat of the forge would become plastic and fail? When the forge turns off, how do you keep the hot air in the forge from rising into the blowers and melting them? There were many more.

We were really impressed by the polished final appearance of the forge, and the cleverness of its design. Everything is well thought out, and you can even increase the height of the forge by propping it up on more fire bricks. We hope [EssentialCraftsman] will continue to produce such high quality videos. We also enjoyed his episode on Anvils as well as a weirdly informative tirade on which shape of stake (round or square) to use when laying out concrete jobs. Videos after the break.

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From Shop Floor Dust To Carbon Steel

August 1, 2016 by Gerrit Coetzee 15 Comments

[Chandler Dickinson] did his monthly sweep of the floor in his blacksmith’s shop when it occurred to him that all that metal dust had to go somewhere, didn’t it? So he did the only reasonable thing and made a crude foundry out of cinder blocks, melted his dirt in it, and examined what came out the other end.

His first step was to “pan” for steel. He rinsed all the dirt in a bucket of water and then ran a magnet at the bottom of the bucket. The material that stuck to the magnet, was ripe for reclaimation.

Next he spent a few hours charging a cinderblock foundry with coal and his iron dust. The cinderblocks cracked from the heat, but at the end he had a few very ugly brittle rocks that stuck to a magnet.

Of course there’s a solution to this non-homogenous steel. As every culture with crappy steel eventually discovered, you can get really good steel if you just fold it over and over again. So he spend some time hammering one of his ugly rocks and folding it a bit. He didn’t get to two hundred folds, but it was enough to show that the resulting slag was indeed usable iron.

He did a deeper examination of the steel last week, going as far as to etch it, after discovering that the metal sparked completely differently when sanded on one side versus the other. It definitely needed work, but all seemed to have worked in the end.

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Blacksmith Forge Made From The Bathroom Sink

November 4, 2015 by Bil Herd 57 Comments

The sweltering heat had finally moved on and Giant Tick season was coming to a close (not kidding, they are HUGE here), when I decided to fire up my hacked together blacksmith forge made out of an old bathroom sink and aquarium stand.

In the age-old formula I needed to supply an air source to a fuel to create enough heat to make iron malleable. I got the idea that this particular bathroom sink might be a good candidate for a fire bowl after I banged my shin with it and then cursed at it. It was clearly made of cast iron and as proof it was clearly unfazed by my tirade of words which I hope my son has learned from the Internet and not from listening to me remodel the bathroom.

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Retrotechtacular: Häfla Hammerforge Healed

September 2, 2015 by Kristina Panos 13 Comments

Visit any renaissance fair across the United States this fall and you’ll undoubtedly find a blacksmith. He’ll be sweating away in a tent, pounding on a piece of glowing steel set against an anvil. While the practice of the single blacksmith endures today, high-production ‘works of days past required increasing amounts of muscle. The more tireless the muscle, the better. The manual efforts of the blacksmith were replaced by huge hammers, and the blacksmith needed only to turn the piece between impressions and maintain a healthy respect for the awesome crushing power of the machine.

Last week, blacksmith enthusiasts completed restoration work on the Häfla hammer in Finspang, Sweden. The 333 year old hydraulic hammer hadn’t been used since 1924, when operations ceased at the Häfla Hammerforge. The ‘works was built in 1682 and used the German method of forging, which had been introduced to Sweden in the 1500s. Steel production was revolutionized in the 1800s by the Bessemer process, which resulted in a much stronger product. Continue reading “Retrotechtacular: Häfla Hammerforge Healed” →

Retrotechtacular: An Ax Factory Of Yore

December 3, 2013 by Mike Szczys 40 Comments

When your mind’s eye thinks of an ax factory you may envision workers loading blanks into a machine that refines the shape and profile before heading to an annealing furnace. But this is Retrotechtacular, and we’re tickled to feature a look at a different time in manufacturing history. This ax factory tour looks at every step in the manufacturing process at a factory in Oakland, Maine. It was shot on film in 1965 just a few months before the factory shut down. [Peter Vogt] did a great job of shooting and editing the reel, and an equally fine job of converting it to digital so that we can enjoy it on his YouTube channel.

Above you can see the automatic hammer — known as a trip hammer — that is driven by cam action. At this point a lot of work has already been done. Blanks were cut from steel bars by two workers. These were shaped on the trip hammer before being bent in half to create the loop for the ax handle. From there a piece of high-carbon steel was added to form the cutting surface. This brings us to the step above, shaping the two glowing-hot pieces into one.

We don’t want to undermine the level of craftsmanship, and the labor-intensive process shown off here. But we can’t end this write-up without at least mentioning the kitsch that is smoking cigarettes and pipes on the job. At one point a worker actually lights his pipe using a the glowing-hot ax head.

To give you an idea of how this contrasts with modern manufacturing, here’s a How It’s Made episode on axes (although we think whats being made would more appropriately be called hatchets).

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Thundercats, HO!

June 26, 2013 by Brian Benchoff 1 Comment

[Tony Swatton], blacksmith, armorer, and prop maker, has built hundreds of custom swords for hundreds of movies and TV shows. He’s also the maker behind Man at Arms, the YouTube series where weapons from your favorite shows and movies are recreated, be they improbable weapons from a James Bond movie or a sword from a cartoon. This time, he recreated the Sword of Omens from Thundercats. It’s a work of art in its own right, and amazingly practical for a cartoon sword.

The Sword of Omens is one of [Tony]’s more complex sword making endeavors he’s done. The grip is made of seven different pieces cast in bronze, while the hilt of the sword is over a dozen of different pieces of steel welded together. The jewel in the sword was cut from a piece of glass, carefully ground on a lapidary wheel to a perfect dome.

Of course, this isn’t the only weapon from popular media that [Tony] has crafted. He’s also done Oddjob’s hat from James Bond and Finn’s golden sword of battle from Adventure Time.