[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.
Continue reading “Impressive Custom Built Blacksmith’s Forge”
[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.
Continue reading “From Shop Floor Dust To Carbon Steel”
When a large bandsaw broke down due to a cast iron part snapping in two, [Amr] took the opportunity to record the entire process of designing and creating a solid steel replacement for the broken part using a (non-CNC) mill and lathe.
For those of us unfamiliar with the process a machinist would go through to accomplish such a thing, the video is extremely educational; it can be sobering both to see how much design work happens before anything gets powered up, and just how much time and work goes into cutting and shaping some steel into what at first glance looks like a relatively uncomplicated part.
Continue reading “Fixing a Broken Bandsaw with a Custom Steel Part”
Metalwork of any kind is fascinating stuff to watch. When the metalwork in question is in service of the clockmaker’s art, the ballgame changes completely. Tiny screws and precision gears are created with benchtop lathes and milling machines, and techniques for treating metals border on alchemy – like heat-bluing of steel clock hands for a custom-built clock.
If you have even a passing interest in metalwork and haven’t followed [Clickspring]’s YouTube channel, you don’t know what you’re missing. [Chris] has been documenting a museum-quality open-body clock build, and the amount of metalworking skill on display is amazing. In his latest video, he covers how he heat-blues steel to achieve a wonderful contrast to the brass and steel workings. The process is simple in principle but difficult in practice – as steel is heated, a thin layer of oxides forms on the surface, enough to differentially refract the light and cause a color change. The higher the heat, the thicker the layer, and the bluer the color. [Chris] uses a custom-built tray filled with brass shavings to even out the heat of a propane torch, but even then it took several tries to get the color just right. As a bonus, [Chris] gives us a primer on heat-treating the steel hands – the boric acid and methylated spirits bath, propane torch flame job and oil bath quenching all seems like something out of a wizard’s workshop.
We’ve covered [Chris]’ build before, and we encourage everyone to tune in and watch what it means to be a craftsman. We only hope that when he finally finishes this clock he starts another project right away.
Continue reading “Metal Magic: Heat Bluing Steel Clock Hands”
Sheet metal. Beer cans. Pieces of chain. Not items you’ll typically find on the BOM for a custom guitar. But nobody told [Maarten van Halderen] that, and so he threw them all together into a gitaar van schroot, or scrap guitar for the Dutch impaired (YouTube link).
The video shows the build process, starting with plasma cutting and welding sheet steel for the body. The neck is fabricated from rectangular steel tube, with nails serving as frets. Overall it looks like a Les Paul, except for the sink strainer basket mounted in the sound hole and the crushed beer and soda cans tacked to the body for decoration. The chains are a nice touch too. And this doesn’t appear to be [Maarten]’s first attempt at scrapyard lutherie – toward the end of the video we see that the beer can axe joins a very steam-punk looking older brother. They’re both good-looking builds, and the video after the break proves they can sound pretty good too.
For a more classical take on the building of string instruments, check out this post on mandolins and violas. Or maybe you can just 3D print your next guitar?
Continue reading “Gitaar van Schroot – The Scrap Metal Guitar”
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”
Here’s a rose-colored look into the steelworks at Workington, Cumbria in northern England. At the time of filming in 1974, this plant had been manufacturing steel nonstop for 102 years using the Bessemer process. [Sir Henry Bessemer]’s method for turning pig iron into steel was a great boon to industry because it made production faster and more cost-effective.
More importantly, [Bessemer]’s process resulted in steel that was ten times stronger than that made with the crucible-steel method. Basically, oxygen is blown through molten iron to burn out the impurities. The silicon and manganese burn first, adding more heat on top of what the oxygen brings. As the temperature rises to 1600°C, the converter gently rocks back and forth. From its mouth come showers of sparks and a flame that burns with an “eye-searing intensity”. Once the blow stage is complete, the steel is poured into ingot molds. The average ingot weighs four tons, although the largest mold holds six tons. The ingots are kept warm until they are made into rail.
The foreman explains that Workington Works would soon be switching over to a more modern process. As it was, Workington ran a pair of Bessemer converters on a 40-minute schedule, ensuring constant steel production from ore to rail. Between 1872 and 1974, these converters created an estimated 25 million metric tons of steel.
Continue reading “Retrotechtacular: The Bessemer Converter”