Hi everyone!
I'm just getting into blacksmithing and I've been a silent peruser of the site for some time now, just figuring out how I should go about this fun new hobby. Don't expect fantastic start-to-finish photos. My wife will attest to the fact that I'm usually too giddy to start a project and I never take photos before and during, only after.
I was going to go the gas forge route, but then while trying to figure out the refractory cement and all the debates around which one to use, and where to get it, and how to apply it, I thought "Hey, I have an old BBQ. I'll just make a solid fuel forge".
I live in an area where charcoal is available everywhere but coke and coal are nowhere to be found, so that limited my fuel options. Considering I would be using charcoal, I then had to decide whether to go bottom blast or side blast. While I know side blast is generally recommended for charcoal forges, a couple factors made me go for the bottom blast. First off was dealing with ash. Considering I was starting out with a kettle-style BBQ, I figured it would be easier to build in an ash dump underneath rather than trying to trench it out to the side. Secondly, a side blast would have required a water-cooled tuyere (at least if I'm going to do this properly). My workshop doesn't currently have power and I didn't want to run a long extension cord to power a water pump every time I wanted to forge. Therefore, bottom blast it was!
I went with one of those fat and fancy truck exhaust tips from Crappy Tire (the Canadian... I don't know... everything store) coming up through the base, with another 1.5 inch exhaust pipe welded into it on an upward angle. I was able to find a 4.5 inch cast iron grate, which I built into the firepot. For the blower, I went with a cheapy hand crank blower. Although this thing is nothing to brag about, it seems to be doing the job remarkably well. I barely have to turn it, maybe 1 revolution every 2-3 seconds, to get to forging temps. 1 crank per second and the thing is spitting up lovely blue flames. The lining is just a kitty litter/sand mixture rammed, dried and fired a la Frosty's recommendations (spider web and all). I'll probably end up cutting out a section of the side wall to allow for longer pieces to lay flat, but I'll see how everything works before I start breaking out the Sawzall.
While doing one of my fires, I decided to test it out with a piece of 1/4 round bar. I was able to make an ugly little leaf-shaped object, but I'm still proud of the wee guy. I was only able to get into this hobby because I'm building my wife a greenhouse and I told her that if I got into blacksmithing I could decorate her greenhouse... so I better get good at making leaves or she'll be onto me and my shenanigans.
Anyway, I just wanted to share my journey with you so far. I'm looking forward to being part of this community and continuing to learn from everyone!