Problem Solving

Forge Welding

After having searched on many structural steel related forums, so many formulas and terms got me more confused than anything else. All I need to know is: what`s the max vertical load a 2.5 mt long 120 x 120 x 4mm square structural tube can withstand ? Ignoring the especifications of steel, I would assume for safety reasons, the one I have on hand is the lowest resist hot processed. Any input will be appreciated. Thanks. Nelson.

Do many people here use the technique of covering your work with black sharpie before switching grits to make sure you get all of the deep scratches out before moving on to an even finer grit? I've started trying it, and it seems to be helpful. But I thought I'd check and see if I'm missing out on any downsides before I star laying in a bunch of new sharpies. Also, speaking of grits, what are your favorite grit steps when trying to minimize grinder time? I'm current running 36/50 to start, then 100, 220, and 400. Are there better steps? And how do you decide when your belts are too worn out to use anymore? Thanks in advance!

I bought a gas grill push button ignitor for my newly constructed forge. Its a blown burner and my question is placement. For simplicity, I am considering a spark plug for the electrode rather than what came in the kit as it has the mounting issues already addressed. (drill hole, tap, screw it in ) Where is the best placement for the electrode? Anywhere in front of the gas orifice, or as close to the burner nozzle as possible? My thought is to put it near the coupling at the burner inlet. Input?? Thanks, Scott

How does one make one? Brass is my medium, but I can't understand how folks but the impressions in them. I'm sure it's similar to file stitching....

I have just finished making a new firescreen for our open fire, which has a arched opening. I made the frames of the screens (two hinged halves) to match the opening by forging the curve on the horn of the anvil, using 32mmx5mm flat bar. This was a fairly difficult task, is there a easier or better way to make large curves that flow nicely? I haven't got a photo but I can take one tomorrow if anyone wants to see it.

I have replied as best I coiuld to a couple of Mikes questions as I have a lot of times in the past. I believe Mike is really hungry for knowledge and it appears a bit impatient. I wish his mentor would meet his expectations. As that does not seem to be happening any time soon. He asks a lot of questions and That is apparently bothering some of us. Historically this is a reocuring problem since the start of this forum and I expect it will continue with different names for as long as the site exists. But...( you knew that was coming I bet) What is the site aboiut? Why do we answer questions? Is this not something we wish to deal with do to the volume? The content…

I just bought 3 tons of what was called "smithing coke" from Utah. I bought it with a group of smiths here in the PNW to get the price down to a reasonable point. I am not sure of the exact origin as I was not part of setting up the deal. Good quality coal seems to be no longer available in our region, since Harry's Leather stopped carrying Cumberland Elkorn a few years ago. The coke is very clean, all about the size of a walnut , with virtually no fines. The clinker is harder and glassier than from coal. I am having a hard time getting it to burn as really as hot as I was hoping for. I am using a standard rectangular Centaur/Buffalo firepot with a Dayton electr…

what is an effective etchant to etch graphite? i wan to remove the graphite from substrates. if any, what would be useful for etching graphite? thanks.....

Ok I got a new post vice this morning for only $60 in good shape for the most part but the spring doesn't work. It's made from an old file. other then that and some miner rust and the leg is bent some its in almost new shape. I will have pics up in the next day or two. :D

oh ok.well do you have any files or pages about hammer contol that i may read over?

Can alcoline be used as a forge welding flux?

I recently acquired a large Reed Mfg no. 205 bench vise. It weighs almost as much as my anvil. It had a swivel base which is broken. I'd like to repair it although if that's not feasible I can always just hard mount it. My initial thoughts are to cut off the broken part, thread and tap some holes, bolt a plate on the bottom and weld a ring to the plate to support the outer portion of the vise. Of course, the difficulty would be getting multiple positions for the holdowns to attach to. Anyone have any other solutions. Like maybe someone has an old, unsalavagable 205 and they'd be willing to sell the base

Does anybody know what this stuff is called or what it is?its extreamly high in carbon.

I am looking into a sculpture project right now that ideally would see me layering up a frame constructed from 10-12mm mild steel square bar with panels of 1.5mm sheet mild steel. What I am trying to establish is how long the whole piece would/could potentially last outside in our nice damp British climate. A rusted finish is required and there will be lots of gaps in the plates on the frame but none big enough to get into and seal out from. Anybody got any ideas on this?

Another strange question: I live 'bout 100-plus miles from the nearest Wal-Mart, movie theater, hospital, etc, and some folks here want to start a recycling program. Well, it involves hauling, which is expensive. As a confirmed scrounger, I said, "why don't we keep the resources close to home? Let's melt down our own steel cans, aluminum cans, etc, and use the resource for ourselves, instead of paying someone to haul away a valuable resource." Of course, I don't have the slightest idea about how to build a furnace that could melt these things. It'd have to burn coal or wood- the gas would be as expensive as hauling the stuff outta town. Any ideas?

Along with smithing, I'm a blackpowder enthusiast. I have a non standard flintlock on my rifle and would like to make replacement springs for it. Any suggestions for materials and processes would be helpful.

Is there a safe, dependable way to rehab an abused tool that has been mushroomed? Is it case by case? I realize that some may be too far gone but are there some guidelines on how to make that decision? How does one prevent mushrooming?

I'm in the design phase of a new forge and have some questions. These questions have probably been addressed and if so I appoligize. I am thinking about a forge body that is made of soft refractory fire brick, this will be lined with hard fire brick 1.5" thick. The whole forge will then be skinned with 12 gauge sheet metal. The doors, both front and back would be soft fire brick mounted in a track so they can be adjusted. The sheet metal top will be removeable so the forge can be relined if necessary. I have been looking at the possibilty of two 1 inch side arm burners mounted vertically. The forge chamber is 18"x6"x4.5" Total area is 486 cu. inches. Burner orifice is …

Hi guys, i've been doing ornamental iron work for some number of years like gates, fences handrailings furniture and custom work as well. All these years i've tried to make scroll jigs but they ALWAYS turn out looking like scrap junk. I've just been bending the scrolls around different sizes of pipe and whatever else i can find that has the same radius i need. Can anybody tell me the best, most effective way to make a scroll jig or where i can buy them already made because it would make my job a lot easier because im doing ornamental iron work full time business now and i depend on it to put food on the table and pay the bills. I really would appreciate any suggestions. T…

While building my current forge I called the manufacture of the fiberboard and blanket that I'm using to ask about expansion when heated and the guy on the phone assured me that it does expand. He added that I would have to allow for that in my designing. Later I called a company that is using the same fiberboard/blanket on a regular basis to build furnaces and industrial kilns and they assured me that it shrinks when heated. Both people gave me numbers that they where reading off of some product information chart but obviously they where not reading from the same chart. :confused: so, does it expand or contract? what's your experience?

Does anyone have advice on where to an instruction book or online tutorial for wiring electric motors? I have a 5 hp 3450 motor from Tractor Supply and need a parts list for the starter as well as a little how-to. Any help would be appreciated. Thanks

Hi everybody:).Well i have been doing a blacksmithlight engerneering course in the last 2 months and so far we havent done much or learnt much,and id like to know if anybody out there has tips,knowledge,tricks or anything about blacksmithing id greatly apreasiate you sharing it,since i was a small boy i always loved watching those medievil movies with blacksmithing in them and when i found out that it was a real trade and not only a thing in the movies i knew i had to try it and now im hooked for life. thanx DM aka Shadow forge smith

I want to make my first set of tongs. Have been looking on-line for directions and instructions. Any suggestions? One method referred to some terms related to parts of a tong - not sure what they mean. They were boss, bit, shank, rein. Does anyone know? Thanks in advance.

I used a charcoal forge to heat up some rebar to what I think was an orange heat, placed it on the anvil and only got in about 5 hammer blows before it cooled to where I couldn't work it. :confused: Is this normal?