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Thread: New Welding Forge WIP

  1. #11
    Join Date
    Sep 2009
    Location
    Great Falls, Montana, USA
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    2,742
    I was yaking with a friend last night..... and am seriously considering putting a single layer of kawool along the shell. then filling the rest in with castable. Forges are always a choice between durability and insulating efficiency..... castable is more durable, but not the insulator that fiber blanket is....... just another "lesser of two evils" choice.


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  2. #12
    Join Date
    Sep 2009
    Location
    Great Falls, Montana, USA
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    2,742
    OK....got the pics of the rest of the forge build processed and upload to photobucket.....

    Had to weld the burner holder in place.....Used some sch 80 pipe, then drilled and tapped three 1/2-13 holes located approx. 120 degrees apart...





    Next I built the forms. 10" diameter concrete from tube from Home Depot. 19" piece, split down each side. I used some 1/4" plywood ($5 for a 1/2 sheet at Home Depot), and cut 6" wide X 24" (just because it was that size) pieces to fill in the rest of the form.



    I used duct tape to put the form together....hopefully that will make it easier to get the forms out once the castable cures enough...



    I also picked up a 2", sch 40 PVC conduit, 90 degree. I had to heat and form it to get the radius I needed. But the idea was/is to form a channel in the castable that will "guide" the burner flame around the inside. After getting the dent I needed, I sawed the PVC with a taper around the curve that terminates about mid way on the opposite side of the forge that the burner enters.









    I also used the 1/4" plywood to fill the front and back "doors", trying to ensure that castable would cover most of the steel portions of the doors.....again....used the duct tape to keep things in place.







    Since I had a limited supply of castable, I decided to do a "hybrid" forge.....used 1" of #8 density kawool next the shell, and used the castable for everything inward from there....





    5 bags of Mizzou 3000F castable later......







    Now to leave it alone for about 2 weeks.....then try to take the forms out. After that I suspect it will be a month or so before it will be cured enough for some firings.
    Last edited by EdCaffreyMS; 02-24-2016 at 07:17 PM.

    www.caffreyknives.net
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    "Nobody cares what you know.....until they know you care."
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  3. #13
    Join Date
    Mar 2014
    Location
    Kearney, MO
    Posts
    1,743
    Wow Ed that is looking good. So one inch of kaowool and how thick is the castable?
    pressonknives@gmail
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  4. #14
    Join Date
    Nov 2010
    Location
    portland
    Posts
    70
    very nice. this is looking gooood, and the WIP is very informative. thanks, i'm looking forward to seeing how this finishes up.

  5. #15
    Join Date
    Sep 2009
    Location
    Great Falls, Montana, USA
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    2,742
    Justin: The castable is about 2 1/2" thick, give or take a bit from spot to spot. I intentionally made the castable a bit thicker on the front, and the off burner side. Historically, these have always been the parts of a welding forge that fail/need repair first, so taking that into consideration, I tried to beef those areas up a bit. The one thing I totally forgot to mention in the WIP was putting a hole on the upper left side near the back.....for a thermocouple.

    www.caffreyknives.net
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    "Nobody cares what you know.....until they know you care."
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  6. #16
    Join Date
    Apr 2010
    Location
    Marlette, Michigan, United States
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    5,231
    Dang Ed. That thing is going to be EPIC! Thanks for sharing the images and give such good explanation of the process so far. If I were a betting man. I would have to put my money on "Ed for the win"
    God is GOOD, ALL the time!!!

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  7. #17
    Join Date
    Sep 2009
    Location
    Great Falls, Montana, USA
    Posts
    2,742
    After checking on the new forge this morning, I was pleasantly surprised to find that it appeared cured enough to remove the forms....so I did. It wasn't too tough of a job. I cut the tape with a razor knife, and pried the forms out of the "door" areas. Luckily, everything came out smoothly.



    I suspected there would be some dressing up needed on the door openings, so I grabbed a ceramic tile file that's been in the shop for years.....



    After a bit up filing with it, I got the front and rear opening cleaned up nicely........





    I'm thinking that forming in a "flame channel" might have been a good thing. Guess I'll find out when it cures enough to put in place and fire. A little bit of the duct tape got hung up in the curing refractory, but my guess is that won't be any big deal....it should just burn out when I fire the forge for the first time.



    Looks like my measurements worked out correctly for using fire brick in the front and back "doors"... here's a pic of the front door...from inside the forge....



    I'm thinking that after it cures, I'll take the torch to the inside to burn away all the stuff left over by the forms...... gotta make sure the surfaces are fairly clean prior to coating the interior with ITC-100.

    As it gets closer to completion, I'll take some pics of the burner assembly, and might even do some video.
    Last edited by EdCaffreyMS; 02-29-2016 at 04:51 PM.

    www.caffreyknives.net
    Caffreyknives@Gmail.com

    "Nobody cares what you know.....until they know you care."
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  8. #18
    Join Date
    Mar 2014
    Location
    Kearney, MO
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    1,743
    That is looking good, so will the flame swirl in there like a little tornado or what is your goal on a vertical forge?
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    Instagram @pressonknives

  9. #19
    Join Date
    Sep 2009
    Location
    Great Falls, Montana, USA
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    2,742
    Thats the idea. Another reason I like a vertical forge for welding is because the billet is suspended in the forge... rather then laying in a puddle of flux, as generally happens in a horizontal forge. I'm putting the forms together for a lid.... gona build it just reverse of the forge..... kawool to the inside, and the rest castable.

    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. #20
    Join Date
    Oct 2009
    Location
    Everett, WA
    Posts
    688
    What a great thread, Ed. Interested to hear how this ends up performing.
    Erin
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