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Hypercon
Make Your Own Forge
A quality heavy duty forge can be made for under $50 USD. The following design has been used extensively both with bellows type blowers and rotaries and has produced supurb results. The forge consists of two basic pieces - the tuyere and the forge base.
The Tuyere
The tuyere is constructed of galvanized plumbers pipe. While the size can be altered, a heavy duty forge requires 2" diameter piping. As a general rule the diameter of the pipe used roughly corresponds to the maximum size square rod that can be effectively heated to welding temperature in a reasonable time (assuming a proper volume air source). The following exploded drawing shows the various pieces used in construction.
The pieces are threaded and simply screw together. The flange can either be welded to the bottom of the base plate of the forge or alternatively dropped in from the top and then screwed onto the upper pipe. We have always chosen the latter method for ease of replacement. The "t" permits the insertion of a cleanout plug at the bottom. While prices will vary across the country, these pieces can be purchased from a builder or plumber supply in 2" diameter for about $20 USD.
The Forge Base
The base plate should be made of steel. For a 2" tuyere that will see a lot of action, the plate should be between 3/8 and 1/2 inches thick. Sheet metal of any type will rapidly burn out as will 1/4 inch plate over time. The ideal size for the plate is 30" x 30". In 1/2" steel, such a plate will weigh approximately 125 lbs. At 18 cents per pound for salvage thats $23 USD. Add a $5.00 cutting fee for the hole in the center. A stand can be made using 4x4 fence posts with 2x4 cross bracing for about $15 USD. For an average height person, the stand should be between 30" and 35" high.
Portable Forges
This portable forge was recently donated (like, free) to Lytton Creek by Noel Ferah, a retired computer dude with NCR (vacuum tubes & mechanical levers when he started out), black powder hunter and all around good guy who found this thing chained to a tree in the panhandle of Texas and saved it from becoming a daisy planter. On his way back from Colorado elk hunting with a Springfield musket, no less.
We think its either a riveter's or farm forge from between 1880 and 1915. There are no markings on it whatsoever. The fire box, tuyere and large wheel are all cast iron. The bellows is a small version of the standard No. 40 rotary crank. This model has locations for the connection of either an electric motor or the main wheel by probably leather belt on the latter and v-belt on the former. The wheel is worthless as a method of cranking the bellows even when connected using a mid-20th century 6" cast aluminum flywheel mounted on the main wheel spindle. We believe that this more likely than not is either a commercial riveter's forge or a small independent farm or grange manufacturer's product.
We are considering hooking up a foot feed for cranking the bellows, believing this to be the most logical option. If you have prints, photos, memories, etc. about either this general forge type or good plans for foot cranks of any type, please e-mail wb3@lyttoncreek.com