Big Forge

[Dillon Sculpture]

Well I figured I would give it a try... The pic of the inside is after 8 minutes of fire. I will eventually build a support for the top that will raise and lower independently. Hoping I'm around 800,000 1,000,000 BTU to forge some 6" square B)

[timgunn1962]

That's a pretty serious setup.

 

If you are running on Propane and my sums are anything like right, that's 40-50 lb/hr of gas through it. What is the gas supply system?

[ThomasPowers]

And I hope you have a very large hammer indeed!  When I did my 2.5" sq stock a 100# LG and a 200# Chambersburg was used and I would have liked MORE POWER!

[jeremy k]

Michael - I would think you could just call NC TOOL, and ask what the out put is on the 6 burner tunnel forges they make - (looks like the burners from one just like mine).

[Jim Kehler]

Looks like you and the 750#er are going to have some fun, might want to think about an air curtain for when it's all up to temp.

[Dillon Sculpture]

250 gal. tank, I just hope gasification will happen quick enough, if need be a second tank should do the trick! I do like the idea of an air curtain, I am working on moving all my forges outside undercover which will help. If the test run goes well I will build a larger platform to stack wider and taller. I'm sure more combustion space for the big stuff will help and it will be nice to have a configurable forge. Trying to figure what I can forge with a limited crew is the problem at hand, anybody want to run a steam hammer! 

[jeremy k]

Michael - Are you burning the 6 burners PLUS the Johnson at the same time?

[Dillon Sculpture]

Yep thats the plan, the pics are of them both on for 8 minutes round about. Wasn't sure if the forced air would influence the NC burners...

[ianinsa]

Mike, you should pm Alan Evans in the UK and get him to send you a pic of his adjustable large forge(better yet ask him to post a pic), I can't remember his setup exactly(I blame age/craft) but I remember thinking that his concept was really simple and clever!

Once you stick the 6" in how does it affect the top to bottom 'swirl' for want of a better term?

[Frosty]

Uh, I'm not sure what to say, that's one serious gas appliance.

 

Johnsons were (are?) famous for coming to not quite welding heat on natural gas and exceeding it on propane. I'd have to take a tape to my Johnson 122a but I think 6" would fit easily. Being gun burners you can close the lid all the way, the leakage around the lid is all the exhaust it needs.

 

It's been a long time since I've been around a Johnson trench forge in operation, I've never lit mine. I got it as part of an all or nothing buy and have no need for something that size. I wish I could come over and watch that puppy in action, I'd stay out of the way, honest.

 

Frosty The Lucky.

[Dillon Sculpture]

I would love to see Mr. Evans set up along with all the other stuff he does! I used the Johnson 133 (big one) to forge parts of my sculpture Aileron, 3" x 8" x 20" plate never felt like it could reach a good forging temp. I also forge 5" round in my 6 burner with little room around the material, it was not practical either. I think this will have the extra BTUs needed to get the 6" hot in 45-60 minutes. I'm pretty surprised I didn't get any offers to run the big hammer!  :P

[Jim Kehler]

If you were a bit closer I'd be there in flash, I'm sure it must be perfect weather to be forging 6" in Atlanta.

[lupiphile]

Howdy Mr.Dillon,

                           Alan Evans has posted about his gas forge. I believe if you look through his posts on coal forges he goes into depth about his large gas setup. Also methinks you need some doors on that thing, I suppose that wouldnt be so much of an issue once you have that billet of six inch stock in there, but it sure would come up to temp faster. I'm looking forward to what you have planned with that thing. I'd love to run an 800lb hammer, I sure wish I had the time for a field trip. Are you gonna get a chance to get to this years conference? Take care, Matt

[Dillon Sculpture]

Thanks Matt, your welcome to stop in if your ever down south! I will post up a bit about my next sculpture when it gets rolling, 12' tall but less than a ton  :D here's a pic. Not gonna make the conference, was but I have been invited to demo at The High Museum of Art in Atlanta. 

[lupiphile]

Look you up I will.......oh yes......(bleary slackjawed day-dreamy face, steady stream of drool visibly punctuated by the rhythmic thumping of 800lb hammer) 

                            Take care, Matt

[Dillon Sculpture]

Ha, you'll fit right in with the (how did you say?) coke headed addles that clean my shop   :P

[monstermetal]

It might be more efficient to burn dollar bills directly….. :-)

[Dillon Sculpture]

It will defiantly suck! I was pleasantly surprised to get a special fill rate of $2.50 a gal. last time before I think it was close to 4 bucks! If I were to use the whole tank you know I would done some work  :D

 

I had a sculptor over the other day and we had been discussing the new sculpture, he asked why I just wouldn't hollow form it? I had been asked this before, about Aileron. Considering the amount of time to cut, weld and finish all the pieces in a sculpture like this I can see no way to come out ahead. Also the longevity of the work would be severely diminished, plus I just like to beat on stuff!

[monstermetal]

Steel is real man,  I am always disappointed to find something "empty"    The weight of a sculpture adds to its value and allure

[lupiphile]

Hollow formed? Did they also ask why you don't sell your hammers and get air conditioning ? I mean c'mon.........Matt

[Tim S.]

The number of burners is not the whole story. To heat big stuff in a slot forge you want to have thermal mass- i.e. refractory cement/brick. When I did big work out of slot forges we would often come in early to start the forges and get them hot- and I mean HOT before putting work in. Then the next key was to keep them sealed up as well as possible, Use firebricks or ceramic fiber blankets to keep the heat in.