Der_Hannes Posted August 1, 2014 Share Posted August 1, 2014 Hello! I did use the search engine but i did not find an illustrated topic with end result pictures or pictures of the problem itself. As i have a big crack in my firepan i wanted to know how to fix it. I hope someone did this before and could tell me what to look for, and what to avoid. Maybe a picture of a fixed one would be great. So here is the problem child: The crack is quite huge and the pan has been used very much, so i think welding isn't that fun or even impossible because of the burnt material. I 've heard something about riveting a plate: Won't this cause more tension, when the pan gets hot? And riveting an old rusty cast part!? Dangerous to turn it into rust and pieces? I thought about perparing a thick walled sheet with holes about 8mm for 6mm screws and cut threads in the pan. I really love that forge, and want to save the heart of it. Replacement of the pan is a bit difficult as i can't find a fitting equal one with 220x 250 mm and such large bolts. I hope someone can help me with the experience he made while repairing his own, best would be pictures or description. Greetings, Hannes Quote Link to comment Share on other sites More sharing options...
the iron dwarf Posted August 1, 2014 Share Posted August 1, 2014 if there is an iron foundry near you could ask about getting a replacement cast, it would not be cheap to do though. bolting some plates on would cost a lot less and may work for a long time Quote Link to comment Share on other sites More sharing options...
ThomasPowers Posted August 1, 2014 Share Posted August 1, 2014 Rather than try to repair that one: fabricate a replacement out of steel plate. You will be much happier in the long run. Quote Link to comment Share on other sites More sharing options...
ironwolfforgeca Posted August 2, 2014 Share Posted August 2, 2014 thats not worth fixing !!!1 find a welder & have him fab one up use that one for a pattern Steve's welding Quote Link to comment Share on other sites More sharing options...
Der_Hannes Posted August 3, 2014 Author Share Posted August 3, 2014 Thank you for the replies so far! @the iron dwarf: I think casting a new one could even become more expensive than buying a whole new hearth as i don't know a friend which is casting. @Thomas Powers and IronWolf: I think i will give riveting or bolting a go for short term solution ( i need that one in a week again ) And weld a new one for long term. I would use 8mm/0,31" plate as sheet. Is this too much or less? Next week i 'm going to get it in the workshop and i try to disassemble it. Then sandblast or wirebrush. And trying to rivet something on that one. Greetings, Hannes Quote Link to comment Share on other sites More sharing options...
arkie Posted August 4, 2014 Share Posted August 4, 2014 Hannes, I am assuming from your description in your original post of it being "cast", that the firepot is cast iron. If so, hop over to www.weldingweb.com and sign up for that forum. They have some very experienced welders over there that may help you weld it up. First, explain your situation clearly, including any work you have previously done, and your objective (patching the crack). Several members on the forum have experience welding cast iron exhaust manifolds on cars/trucks, which do indeed get red hot sometimes, probably similar to some firepot areas. It would include grinding out the rusty areas, drilling holes in the ends of the cracks to prevent them spreading further, pre- and post- heating of the part and using certain stick welding rods. Be sure to post pictures like you did here...they LOVE pictures and they best show what your problem is and helps determine the best solution. You might even be able to find welders where you live who repair cracked cast iron parts which are exposed to high temperatures. Quote Link to comment Share on other sites More sharing options...
Der_Hannes Posted August 12, 2014 Author Share Posted August 12, 2014 Hello again! @ arkie: Thanks for the Info i will post some pictures there because of strange acetylene welding with copper rod... which appeared when i rough cleaned the lower part) here is the condition of the pan itself: close up: So i welded a new pan out of mild steel and filled the gap between pan and lower part with oven rope seal. I cold tested it and i was impressed how much pressure such a small ventilator produces. Now i hope the pan won't combust because it's only mild steel. Tomorrow i will work with it for 5 days each 11 hours... if everything holds together. I really love its design... hold together by hope and ignorance of different fore owners and me ;) i will keep you informed how it worked. Greetings, Hannes Quote Link to comment Share on other sites More sharing options...
Frosty Posted August 12, 2014 Share Posted August 12, 2014 Good decision making a new one rather than trying to repair the broken casting. If you still have them put the patterns you used for the one you just made in a safe place, you'll probably want to do this again in a few years. Mild steel isn't going to just burn up any more than cast iron will, it's good for years of hard use. There's nothing strange about the "copper", probably bronze repair. Welding is fusing the parent metals with a like metal, literally melting them together. What the copper alloy is is brazing, NOT welding. Brazing is hard soldering and a standard repair method for cast iron before the modern cast iron alloy welding rods became available for a reasonable price. Unfortunately, once brazed welding is out, the brazing rod will do a good job of preventing a weld of most any kind. Frosty The Lucky. Quote Link to comment Share on other sites More sharing options...
arkie Posted August 13, 2014 Share Posted August 13, 2014 Good job, Hannes. x2 with Frosty; glad you went with a new firebox instead of trying to patch the old one...it was in pretty bad shape. Enjoy and forge ahead! Quote Link to comment Share on other sites More sharing options...
Der_Hannes Posted August 19, 2014 Author Share Posted August 19, 2014 Servus again! After firing the forge for 5 days i'm glad to tell, that it works really propper now! Firepan didn't burn through. The part below didn' get too hot. The blower didn't start to burn.Kept being tight and the airblow was very strong. I fell in love with my forge again as i can't imagine any better Action-Shot: and pan after some days: Frosty: Thanks for the Info about Brazzing! arkie: Thanks! Yep the old one was almost not repairable. Sorry, that this was not an instruction how to repair one, just how to replace one. Greetings, Hannes Quote Link to comment Share on other sites More sharing options...
DSW Posted August 19, 2014 Share Posted August 19, 2014 Sorry, that this was not an instruction how to repair one, just how to replace one. In my book that's a repair. You managed to save the forge, even if you had to replace a part of it. Good job and keep enjoying it for years to come. Quote Link to comment Share on other sites More sharing options...
Frosty Posted August 20, 2014 Share Posted August 20, 2014 My pleasure Hannes. That's repaired, it's working a treat now. That's quite a view. Do scantily clad young ladies sail past often? How do you keep your mind and eyes on forging? Frosty The Lucky. Quote Link to comment Share on other sites More sharing options...
arkie Posted August 21, 2014 Share Posted August 21, 2014 Hannes, you might start a new trend....forging on the beach!!! :D Crank up some Beach Boys classics and forge ahead!! Quote Link to comment Share on other sites More sharing options...
Der_Hannes Posted August 22, 2014 Author Share Posted August 22, 2014 Servus again! @DSW: Thanks and i will definately enjoy my forge. ( i've got some big plans to add and stuff) @Frosty the Lucky: Let's say it was a happy coincidence that the blacken fingernails appeared when i came back ;) @arkie: mhm surfboard- workbench combination, floating wind powered forge... i need to do some blue prints and then -> off the beach into the waves ;) Quote Link to comment Share on other sites More sharing options...
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