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Thread: New Welding Forge WIP

  1. #1
    Join Date
    Sep 2009
    Location
    Great Falls, Montana, USA
    Posts
    2,820

    New Welding Forge WIP

    Its time to build a new welding forge..... for several years I've been using a KaWool insulated welding forge, mainly due to the high cost of castable.... but seems I'm doing much more forge welding these days, and the lining only lasts a couple of months.....in short I'm just tired of repairing, and being down for a week until things cure enough to use the forge again. So, time to "bite the bullet" and spend the money on a forge that should last for several years.

    First order of business is a "shell". My Pal Steve Kelly donated an old air compressor tank to me a while ago.....and its just the ticket for this project. 16" diameter X 24" long. First thing was to cut the ends out, and then split it down each side.......



    I've been forging larger and larger billets, so I decided I wanted a "chamber" size of at least 16" long X 10" Wide. Since the castable needs to be at least 3" thick to perform well, the 16" compressor tank is just right. In order to achieve the distance I wanted, the tank was split lengthwise. First I build the openings of 3/4" X 6" A36, making the front door 10" X 4 3/4". This allows me to stack standard sized firebricks to make the opening smaller, or remove them to enlarge it.....depending on how large the billet is.



    I also built a "back door" that is 5 1/4" X 4 3/4"..... that way it can be closed off with two firebricks when not needed as a "pass through".

    Once the "doors" were welded to the shell, then it was time to add in 8" extensions on each side to create a large oval.




    Now it's "bite the bullet" time......shelling out the approx. $500 for Kast-O-Lite 3000F castable refractory, and the FOB to get it here. The best deal I could locate was $58.90 per 55lb. bag, and $150 FOB whether I they ship one bag....or an entire pallet........ I'm getting 6 bags, which should do the entire lining of the forge, and give me a left over bag for future needs.

    Once the castable arrives, the first thing is to pour the floor, and let it cure for a week, then get the burner holder placement set, and the forms built for the inside. I'll get more pics at it goes along and continue on this thread.

    www.caffreyknives.net
    Caffreyknives@Gmail.com

    "Nobody cares what you know.....until they know you care."
    Visit me at Table 2Q at the Blade Show!

  2. #2
    That's cool! I like what I'm seeing!
    Best Regards,
    -Daniel Rohde-
    www.RohdeEdge.com

  3. #3
    Join Date
    Sep 2009
    Location
    Great Falls, Montana, USA
    Posts
    2,820
    Planned on ordering the refractory today..... but the gal I deal with is out of the office. Might be next week before the order is placed.....and who knows how long to freight it here. The plan for now is to pour the floor first, let that cure for a while, then get the burner holder placed correctly......then i MIGHT be ready to pour the liner.

    www.caffreyknives.net
    Caffreyknives@Gmail.com

    "Nobody cares what you know.....until they know you care."
    Visit me at Table 2Q at the Blade Show!

  4. #4
    Join Date
    Dec 2014
    Location
    Saunders County, Nebraska- west of Omaha
    Posts
    212
    Thanks, thanks, thanks, for posting this WIP! Can't wait to see more!

  5. #5
    Join Date
    Jun 2011
    Location
    Nova Scotia, Canada
    Posts
    1,812
    Cool build I'm going to watch this close.

  6. #6
    Join Date
    Aug 2015
    Location
    Valley of Va
    Posts
    472
    Watching with both eyes open. Ed
    I am always doing that which I cannot do, In order that I may learn how to do it. --- Pablo picasso

  7. #7
    Join Date
    Sep 2009
    Location
    Great Falls, Montana, USA
    Posts
    2,820
    Finally got started pouring the new welding forge today. I've never built one this large.....so its "learn as I go".

    At first I wasn't going to put a steel floor in it...... but figured that since it's likely going to take a forklift to move this one....it might be a good idea. I'd hate to see all that castable pop out the bottom a end up as a pile of rubble on the shop floor!

    Mixing tube, castable, water, and all my homemade tools for mixing and getting the castable in place. I put a thin layer of castable in the bottom, then added 5 fire bricks as "filler" to save as much castable for the walls as possible. I spaced the bricks, filled the gaps, then put about a 1" layer over the top. Now its going to be about a week of cure time before I can locate and install the burner holder, then it will be building the interior forms, and then hopefully I can "fill er up"

    More to come!








    www.caffreyknives.net
    Caffreyknives@Gmail.com

    "Nobody cares what you know.....until they know you care."
    Visit me at Table 2Q at the Blade Show!

  8. #8
    Lookin' good Ed!
    Are you going to need to use forms for the walls or is the refractory thick enough to stick in place with thin layers?


  9. #9
    Join Date
    Sep 2009
    Location
    Great Falls, Montana, USA
    Posts
    2,820
    Its gona need forms. The plan is to buy a length of 10" diameter "sona" tube (concrete form), split it down two sides to create two 1/2 circles. Those will be the radius at the front and back doors. I'll use 1/4" plywood for the sides. I'll use a heavy cardboard tube to form the burner hole, and a hole for the thermocouple.....that way if I can't get it all out when everything is cured.....it will just burn out when I burn the forge. Once the castable cures out, it will get a slurry coat of ITC-100. I'm also gona nose around some local tile stores and see if I can find some ceramic tile to act as a catch pan in the bottom for flux.

    www.caffreyknives.net
    Caffreyknives@Gmail.com

    "Nobody cares what you know.....until they know you care."
    Visit me at Table 2Q at the Blade Show!

  10. #10
    Good idea with the cardboard form tubes. That's the part I was curious about.
    If the flat sides get stuck, a piece of pine might be better to burn than ply?

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