31/07/2024
A package arrived from Lithuania today and the peasants are rejoicing.
After a year learning the basics with a kludged together forge that had a piece of garbage home-made burner, then several years of refining my skills by working with with a cheap entry-level model, I've sorted through what I need and have started ordering the parts that I need to put together a top notch forge.
This new forced air, high efficiency burner is the key piece. Instead of the flow of fuel sucking air into the burner, my air compressor will shoot a high pressure jet of air in, increasing the efficiency of the burn by over 500%. Using less fuel, this unit will produce over 300,000 Btu per hour compared to the 70,000 Btu max of the burners in my current forge.
While a forced air burner can't make propane burn any hotter than its max burn temp, it does make pretty much all of the propane burn at its hottest possible temperature, and because of that, the forge temp will be much higher than my current set up. Right now, I can barely get high carbon steel hot enough to forge weld, but with this new forge, I should be able to quickly get just about any steel hot enough to weld and I'm looking forward to trying to mix layers of this and that to see what I can create. I'm particularly keen on layering spring steel with high-nickel content tool steels for some chef's knives. I also have a bunch of old disks off of cultivators. That's some incredible steel, super hard, super resilient and corrosion resistant, but it needs a higher temp to work. And if I can get it to weld with a spring steel, that could be some wow level stuff.
Now to build the forge itself. I have a plan for making an adjustable configuration forge, where I can adjust the size and shape of the forge interior to suit the task at hand, small for getting Damascus billets up to welding temp quickly, long and thin for drawing out the blades, then wide and short for working hatchet heads and cleavers. I'm also going to keep my old double burner forge and design the new one so I can marry them end to end for when I heat treat long blades.