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I Forge Iron

Claying a forge...yes, another question on the subject


Kozzy

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I know it's been thoroughly flogged as a subject in several posts but I need to address a claying situation which has a little bit of a twist to it rather than being SOP.

The museum has the forge shown in the attached photo which, after a bit of restoration, will be used primarily for display but will also serve rare duty as a demonstration forge.  I'd like to clay it not only because it's a good idea, but to show visitors that claying is something they need to do in their own forges (when it's appropriate).  A heck of a lot of people who have similar forges which they want to monkey with have never heard of claying so it's a subject I'd like to broach in our displays.

The issue isn't claying in general--that's clear in past posts.  I was wondering if there might be a stronger/lighter/improved claying mix for our situation.  As a display forge, it needs a mix that isn't soft or prone to crumbling...possibly even surviving (sort of) if some jackass lets their unruly kid knock the thing over or bang on the clay with one of the hammers in the area.  It should also be light enough to not be too top heavy or make carrying the thing outside to use too big a chore.  Of course it should survive being used hot a couple of days a year while retaining all the good "display" qualities for the 363 days it just sits.

I can think of a couple of possibilities--for example upping the portland cement a little for structure: However the spalling issue might increase.  Maybe adding some vermiculite to the mix for reduced weight but that reduces strength a bit.  Glass fibers?  Alternative clays? Unobtanium?

Just looking for any suggestions that might be better in our kind of oddball situation than the standard mix.  I can always go standard if nothing really helps but I figured someone might have alternative ideas.  I'd be willing to toss some money into better materials if they give better results so keeping it "cheap" is not really a primary goal like it is for many people.  It will never see weather so the only moisture problems involved would be humidity related (and we don't get bad humidity here).

Thanks.

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I'd make it a two part job. clay around the air grate for say 6" dia with a fire clay sand mix and a pinch of Portland cement so it will take a little real heat. But I'd clay the rest of the pan with a light mix, vermiculite for aggregate cemented with a fire clay Portland cement mix. If you add about a capfull of Elmer's glue to the gallon of water you mix the mud with it will stick better making the pan "clay" more durable.

Heck, you can add food coloring to the water if you want it to look like bank clay.

The above is where I'd start my experimenting. The duck's nest mix would be my standard claying mix with the understanding it'll need to be redone if it gets roughed up. Just mix a couple gallons up dry and tape directions on the bucket lid if you're not there when it needs patching.

The light "clay" mix is unknown territory for me though I know it can be done. I'd give the inside of the pan a good coat of Rustoleum first though because the clay WILL trap moisture. Heck it even comes in rust red maybe give it a shot of phosphate primer to be sure.

Oh claying a forge doesn't need be thick it's just there to disperse heat evenly not as a heat shield. 1/2" is plenty unless you're going to be building REALLY HOT fires dead center.

Frosty The Lucky.

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