Hello!
First off, I am little more than a complete beginner with 20-30 hrs at an anvil between two classes this year. I certainly have much to learn.
With that said, I am in the process of building myself a forge. I am using Wayne’s propane forge design with a forced air burner. I intend to begin forging tools to satisfy my tool acquisition syndrome and enable my hobbies. I plan to begin with tongs, chisels, gouges and drawknives but I also would like to be able to make hardy tools, hatchets, hammers, etc.
I have materials and supplies on order including 20# kast o lite 30, 8# ceramic blanket 1”thick, fumed silica, and matrikote.
I plan to use a 5 gal air tank (slightly smaller than a 20# propane tank) as the forge body that is approximately 10” in diameter and 24” long. Using the basic guidelines for lining it, I expect my forge volume to be roughly between 450 and 550 cu in with the ability to increase that volume based on Wayne’s hinged body design. As far as the forge body is concerned, I have so far only cut it in two along it’s length.
As far as the burner goes, I have made a ribbon burner using John Emmerling’s design. I followed the directions on Wayne’s site with some deviation. Using 3” square tube, I cut a length to 8”. The home store I bought black pipe from did not have 2”, so I used 1 1/4” instead. When it came time to mix the mizzou, there were conflicting instructions between the manufacturer and Mr. Emmerling. Foolishly, I chose to follow the manufacturers instructions. This made for a very dry mix that is not appropriate for making a ribbon burner. As you can see from the attached pictures, there is a gap between the castable and the body. Luckily, I have plenty of mizzou to make another cast.
I would still like to use forced air on this forge, mostly because I have already purchased the blower to do so...but I have some questions that I have not been able to find reliable answers to.
How critical to the function of the FARB is the larger pipe? Is there a reason I should not use smaller pipe?
How critical to the function of the FARB is the inside baffle? It seems there are conflicting opinions on whether it is necessary.
Since I have to redo the casting anyway, could I get away with an even smaller ribbon burner? Maybe 4 or 5”?
Is it unwise to use a simpler design for a blown burner? Not that I am unwilling to cast a new burner, but in a small forge, could I get away with a straight pipe? Would a baffle be necessary on a straight pipe?
I appreciate any input!
Cyp