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Mad Dave's Five Hour Forge

Discussion in 'DIY and Traditional crafts' started by maddave, Jun 23, 2006.

  1. maddave

    maddave Bushcrafter (boy, I've got a lot to say!)

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    Well !!
    I got bored as I sometimes do... It was raining and Jules said "why don't you go make something in the shed?" What a good idea !! So over two evenings (3 hrs thursday and 2 hrs friday) I made myself a forge... And I took piccies ;)

    Rooting through all the junk in my shed I found just the stuff I needed. An old 12KG gas bottle, some steel tube off a broken garden hammock, the hose off an old vacuum cleaner and Jules' old hairdryer...

    [​IMG]

    Now before you start there are some very important things you must do. 1st wear suitable protective gear as you will be mucking about with cutting disks, grinders, welders and fire. So you'll be wanting boots, overalls, gloves, hearing protection and eye protection :cool:
    [​IMG]

    About a week before you want to begin, take your old gas bottle into a nice open space and remove the valve by loosening it a little with a spanner then unscrewing the rest CAREFULLY by hand. The valve and it's seat are brass so it's quite safe, [​IMG]
    HOWEVER ***DO NOT HAVE ANY SOURCE OF IGNITION WITHIN 100M OF YOURSELF***** as when you take the valve off there will still be a fair bit of LPG in the bottle that will rush out. Once all activity has stopped, fill the bottle right to the top with water, leave for a day then empty it out. The gas bottle is now safe to start chopping up.

    Mark a line around the base of the gas bottle about 16 cm deep (I used the side of a small jerrican as a guide.
    [​IMG]

    Now strap the bottle firmly to your workbench and get Medieval with the grinder !! :D
    [​IMG]
    [​IMG]

    You should end up with something like this....
    [​IMG]

    Now you need to get a bit of steel tubing around 20 cm long and about 4cm in diameter, put it on the base of the "forgepan" and mark around it. Make an inner circle about 3mm inside this mark and cut out the shaded section (I use a drill and jigsaw for this)
    [​IMG]
    [​IMG]

    You can then weld the pipe on. As you can see my welding it a bit like pigeon poo, but as long as it's airtight it doesn't have to be pretty.
    [​IMG]

    Remember safety when welding too "LUKE.....LUKE.... I AM YOUR FATHER !!!"
    [​IMG]

    When you have welded the base pipe on, you will need to weld an old nut on the bottom of it and a T piece about 30cms long after cutting a hole in the side of the downpipe. See pics below. However I'm sure this could be done with large plumbing fittings if need be...
    [​IMG]
    [​IMG]

    The whole base should look like the pic below now.
    [​IMG]

    Now all we have to do is fit the legs, ashflap, hose and hairdryer. but before that you'll need a steel disk about 15/20cms diameter drilled with lots of holes to act as a diffuser for the air. I used an old steel lid off some pot I found in the shed and this just sits over the hole in the base of the forge.
    This is the old lid...
    [​IMG]

    And this is where it sits
    [​IMG]

    OK remember the old nut we welded to the base of the downpipe?... We use that to install a close fitting ash flap that can allow the ash to drop through the forge and also regulate the air pressure by opening and closing.
    [​IMG]

    The legs are simply 3 bits of the old garden hammock tube with a slot cut in each so they sit flush with the firepan. These are simply bolted onto the side.
    [​IMG]

    And now all we have to do is fit the hose and the hairdryer. Ladies and Gentlemen I give you the "Five Hour Forge Mk I
    [​IMG]

    Ok but does it work?? Let's see.... Charcoal in and lit... on with the hairdryer and after a few pensive minutes........ YEEEEEEEESSSSS
    [​IMG]

    It get's the old metal nice and hot too !!
    [​IMG]

    And the good thing about using Charcoal in your forge is that it has another great use when you're done....
    [​IMG]
    [​IMG]

    Well!! It's hungry work all this metal malarkey !!

    Hope this is of use to you.
    This forge is an adaptation of the Viking Metalworks brake drum forge that can be found at the site below.
    http://www.vikingmetalworks.com/firepot.html

    ****REMEMBER SAFETY ALWAYS WHEN USING A FORGE ! FIRE IS DANGEROUS***
     
  2. led

    led Settler

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    Excellent - very inspiring (just wish I still had a garden shed to play in!).
     
  3. andyn

    andyn Bushcrafter (boy, I've got a lot to say!)

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    What a fantastic tutorial, very inspirational!! Well done for doing something constructive with your time when you were bored. :D
     
  4. Big John

    Big John Nomad

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    Brilliant - good work!

    Those gas cylinders are designed to stand up to a lot, so I'm sure it will be pretty durable.
     
  5. Ogri the trog

    Mod

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    Fan-bloomin-tastic Dave,
    I recon the days of using the kitchen range as my heat source are numbered.

    :You_Rock_

    Ogri the trog
     
  6. leon-b

    leon-b Bushcrafter (boy, I've got a lot to say!)

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    nice forge made out of easy to get parts
    you gave a great tutorial aswell
    well done
     
  7. Phil562

    Phil562 Settler

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    Well done Dave, thats the best tutorial I have read in a long time ;)
     
  8. Hoodoo

    Hoodoo Bushcrafter through and through

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    That was so good I'm not going to say a word about those welds. :D
     
  9. maddave

    maddave Bushcrafter (boy, I've got a lot to say!)

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    Cheers guys

    I just figured like me there are a few of us who'd like to try and make themselves a knife or a firesteel etc but don't want to be paying megabucks for a forge, so I looked in the shed and the rest is history. I have had another thought though. If you wanted it as a portable unit, you could go to your local car dismantlers and grab the blower unit from the car heater and hook it up to a 12v battery. Then you could take your forge in the field !! :D

    *Edit

    Ya like me welds then Hoodoo :p Hahahaha I know I have a couple of buddies who are welders by trade. They made me print those pics off so they could take em into work for a laugh........ Can't say I blame em :lmao:
     
  10. British Red

    British Red M.A.B (Mad About Bushcraft)

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    Great tutorial Dave - you have rep!

    Red
     
  11. tomtom

    tomtom Bushcrafter (boy, I've got a lot to say!)

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    dave that is a great tutorial, im going to have a crack at it sometime as tomtom forge mark 1 was "cleared away" and this look much more perminant than a bunch of breeze blocks (that will teach 'em :D)

    you get a rep point!

    ...now where to find an empty gas bottle!
     
  12. redcollective

    redcollective Settler

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    Laybys, creeks, my local woods. :(

    Great to see something useful made from gear that all too often ends up disgarded in the wrong place.

    Any plans for the rest of the gas bottle? A brazier maybe?
     
  13. bloodline

    bloodline Settler

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    FANTESTICAL tutorial and excellent pics well done! Now what are you gonna make with it ? and will you post some more pics when you have forged some bits? :You_Rock_
     
  14. george

    george Settler

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    Nice one Dave - now that metal filing cabinet in the background in one of the pics would make an ideal food smoker!

    George
     
  15. maddave

    maddave Bushcrafter (boy, I've got a lot to say!)

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    Hi mate.

    I'm thinking of making a knife first off, then maybe a few "strike a lights". Just waiting on my flat bar to start and then I'm away !! :D

    Hmmm good idea George (goes to have another look in the shed) :cool:
     
  16. Mad Mike

    Mad Mike Nomad

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    Nice one Dave right up my street

    (Note to self get that welder you have wanted for years)
     
  17. ilovemybed

    ilovemybed Settler

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    Absolutely brilliant Maddave! Had me chuckling all the way through :lmao:


    Equally mad = no need for the adjective. Brilliant :p
     
  18. Singeblister

    Singeblister Native

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    Great tutorial Dave , I am going to make one of those tomorrow :) ,,, the Kebab i mean its made me rather hungry now
     
  19. longshot

    longshot Need to contact Admin...

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    looks good dave.

    great forge as well ;)

    can't wait to see what you make in that. the steel i mean.

    :You_Rock_

    dean
     
  20. demographic

    demographic Bushcrafter (boy, I've got a lot to say!)

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    Good tutorial, informative and the pictures are worth a thousand words.
     

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