Making a coal forge

[Joshua States 1,923]

Well, I finally got this to the point where I decided to make this thing. I would like to go through the building process, but first I have to give thanks to those who have done this before. So, if you are thinking of putting together a solid fuel forge, take heed. These threads were incredibly useful for me and they will aid you too. The folks who posted them and those who chimed in with advice, suggestions and technical data provided enough variants that you can make what you want. need or have the scrap parts laying around.

Whether you have a premade firepot like Justin Mercier did, or you want to fabricate your own like Charles du Preeze did, or you want to go the ancient tried and true method of "a box of dirt" like Gerald Boggs, these threads will get you there. Thanks again to all those who participated in them and provided their knowledge and support.

https://www.bladesmithsforum.com/index.php?/topic/33699-new-coal-forge/&tab=comments#comment-327552

 

https://www.bladesmithsforum.com/index.php?/topic/36783-defend-your-firepot/&tab=comments#comment-358070

 

https://www.bladesmithsforum.com/index.php?/topic/36356-coal-forge-info/&tab=comments#comment-352716

 

https://www.bladesmithsforum.com/index.php?/topic/35057-coal-forge-wip/&page=2

 

I traded a HF anvil for this rusty old wheel rim forge a few years back. It was packed with some sort of white clay that eroded away over the last few years. The fire pot looked solid and the blower needed a little work, but the set-up wasn't what I wanted. I wanted more of a table type where extra coal could be readily available and I wanted it mobile.

 

So, I started dismantling it. The bolts that held it together were rusted so bad, it took a little MAPP gas torch and a half can of WD-40 to get most of them to come apart, Some were so bad and unreachable so the fire-wrench (oxy-acetylene torch) was put to use. The pieces parts.

 

Now to raid the wife's steel yard for frame materials...….

 

 

Edited August 19, 2018 by Joshua States

[Brian Dougherty 1,247]

2 minutes ago, Joshua States said:

Now to raid the wife's steel yard for frame materials...….

I have a great wife, but alas, that is a phrase I doubt I'll ever get to use.

Thanks in advance for posting your build.  I'll be following along.

[Joshua States 1,923]

For the table I have a piece of 1/4" sheet. Well, two pieces actually. The piece I could get was 49" long and 19" wide, so I cut it in half and can make the table about 25' x 39". Then, I cut some 2x2 x1/8" angle iron and built a frame.

Cut out a hole in one of the two pieces for the firepot. As you can see, I put the lower sides of the firepot so they flushed out with the surface of the 1/4" plate. There's a little gap there.

And, used some 1x1x1/8" angles for the fire pot support and to close the gaps between the table bottom and the firepot.

Now some 2x2 square tube for the legs and some 3/16" by 4 " flat plate for the leg gussets. I also added a couple of hand truck wheels and some 5/8" threaded rod for the axle.

Some cross ties to take the twisting motion away, a couple of tool racks and two railroad spike for handles.

Here it is after wire wheeling most of the rust off.

Now it's off to work on the blower.

 

 

 

[Doug Lester 321]

Starting to look good!

Doug

[AndrewB 151]

I'm actually considering making a coal forge again.  I still have a break drum that I haven't used lol it's just been rusting.  I could easily clean it up, Id have to get some 2 inch pipe and a fan.  But I could easily do that.  Don't think Id go as intricate as a metal table but I've already got a fire pot lol.

[Charles dP 528]

Looking good Josh. A had to cut the angle-iron frame down in front of the pot as I couldn’t lay longer objects flat. I may still have to do the same to the other side but I’ve not had to work on anything that long and, for the moment, it stops the coal falling off the table .

[MichaelP 33]

Hi Joshua, nice job so far, looks great! As mentioned by Charles that angle directly in line with the fire pot will get in the way. You only need to remove a small section so you can lay longer stock flat on the table. The "sweet spot" in that fire pot is on a level plane even with the top edge of the pot with about two inches of fuel mounded above the work. The depth of the pile below the work will use up most of the available oxygen giving you a more neutral flame at the top edge of the pot. This especially matters when you're welding and even during normal forging it's nice to have less scale to deal with. Even the small amount of tilt caused by the lip will have your work going in at a less than optimum angle if the stock extends past the edge of the forge table. You can also make a simple flip over gate that can be opened and closed. Close it with shorter work to help keep stray coal on the table and open it as needed. I look forward to seeing further progress!

[Joshua States 1,923]

Thanks for the suggestions Michael & Charles.

I am considering adding a coal stop on either side of the front of the fire pot to create a coal bin on the larger side of the table and removing the current sides of the frame so a work piece can lay flat across the fire pot. The only trouble with that plan is the vertical portion of the frame angle is where all the vertical strength is, and that section is where all of the weight is. So removing that vertical piece will weaken the structural integrity of the frame. I may have to add another support below the current frame to remove that piece.

[MichaelP 33]

You already have nice gussets in the corners, just flip some angle with one leg down and tack it on under what's already there before you cut the up turned leg off your angle frame. the extra face hanging below the table will give you attachment points for a tong rack

[Joshua States 1,923]

8 hours ago, MichaelP said:

You already have nice gussets in the corners, just flip some angle with one leg down and tack it on under what's already there before you cut the up turned leg off your angle frame. the extra face hanging below the table will give you attachment points for a tong rack

Yep. That's what I was thinking about right after I made that last post. An angle iron on the bottom of the side rail 4" either side of the notch should  suffice. (Make it so, number 2.)

Now where did I leave off? Oh yeah the blower.

Here it is before rehab.

Yes, that's an original rheostat speed controller. I was able to get the fan off the motor and dismantled, I also got the R-stat opened up and cleaned, but I could only get minimal access to the internal parts of the motor. A little rust removal, lubrication and new wires and this baby runs great. 

Now I took that cutout piece of plate and a few bits and pieces for supports. Now it's bolted to its own table that is welded to the frame.

A little 3" duct from Home Cheapo and she's ready for business.

The rheostat goes from "Off" to "Full" in a very smooth sweep. So it is capable of very small adjustments.

I plan on building a side-draft hood on the short end of the table behind the fire pot. Then I'll be able to bring it indoors and hook it up to a suitable exhaust duct if necessary.

That's where it stands today. If anyone has any suggestions, fire away. I am all ears.

[MichaelP 33]

Looking good, I love that old rheostat!

[Clifford Brewer 374]

GIT  ER DONE  !!!!!!!.....................

[Joshua States 1,923]

Well, I really cannot believe it has been this long, but I finally did a test run on this puppy. Starting the fire was its own learning curve, but I got it lit.

 

 

Once it was cooking pretty well we started to heat a big piece of 14 ga, sheet to raise a birdbath bowl.

 

 

I was the shop boy and tended the fire while Liz did the shaping and forging.

 

 

[Welsh joel 60]

Can she call my wife and get her in the forge with me?

Awesome!

[Pieter-Paul Derks 274]

Very cool, projects like that are where a coal forge really shines.  I also think it is really cool that you and your partner share a lifestyle.

[Joshua States 1,923]

8 hours ago, Welsh joel said:

Can she call my wife and get her in the forge with me?

Awesome!

 

24 minutes ago, Pieter-Paul Derks said:

I also think it is really cool that you and your partner share a lifestyle.

 

Be careful what you wish for! Sharing a shop space is a deceptively complicated process. Liz has always been a creative person. She has done quilting, Navajo weaving, glass, basketry, and some other art forms I fail to recall. Her attraction to metal came when I bought a MIG welder for my construction business back in 2003. She saw me welding a gate for a client and asked what that was and how to use it. A short time later, we were introduced to forge work by an old friend who we knew through rock climbing. The rest just fell into place as we went along. Now that we used the coal forge for this project, I foresee other things being created in the shop. What is really cool about the design is the mobility. It lives out in the yard under a small cover. I just grab the handles and wheel it over to the shop door when we need it.

 

When I get back from Atlanta next week, I will be trying another axe. This forge should make the welding a lot easier to manage.

[Welsh joel 60]

My wife is a city girl... and 20 yrs older.

 

She doesn't fish. We have a pond.

She doesn't do crafty things. I have a forge, a vinyl plotter, laser engraver, woodworking tools, etc.

She doesn't shoot. I have a backstop, 30 yds and a few toys.

 

She is the people person, I'm the introvert.

 

Opposites truly do attract. Lol. 27 years I've tried to get her interested- no dice.

 

So to me, to have a spouse or partner interested and willing to join in on the fun- is amazing. Congrats and good luck in joint projects. 

Edited May 31 by Welsh joel