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DIY Metal Forge

One of the oldest metal working processes, forging is a great way to introduce yourself to the world of metalwork. The process of heating steel to a malleable temperature is rather straightforward, but a few arrangements can make the activity much easier and more enjoyable, allowing you to produce a variety of metal objects ranging in shape and size. With only a few basic supplies you can build your own forge and start forming steel as you like.

Things You'll Need

  • Empty coffee can (large)
  • Kaowool
  • Propane tank, regulator and hose
  • Spray nozzle
  • Drill
  • Tongs
  • Anvil
  • Hammer (sledge)
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Instructions

    • 1

      Line a large coffee can with one end removed, with 2 inches of Kaowool. Kaowool is a ceramic-based wool invented to replace asbestos which is toxic to humans. This can often be found at insulating or pottery shops. Don't forget to also line the bottom of the can.

    • 2

      Cut out a piece of Kaowool, 2 inches thick, to be used as a door. This should be able to be placed over the open side of the coffee can while forging.

    • 3

      Use a drill to make a 1-inch diameter hole in the side of the can, and remove some of the Kaowool to allow access to the inside of the can. This hole will be used to stick the burner nozzle through.

    • 4

      Connect a solid metal (no plastic gaskets or other parts) spray nozzle, as would be used for watering a garden, to the propane tank's gas hose. Test the apparatus by turning on the gas at the tank and regulator and lighting the tip with a flame. This should produce a blow-torch-like flame.

    • 5

      Insert the piece of steel you wish to heat into the can and place the Kaowool lid over the open side.

    • 6

      Light the gas torch nozzle and hold it to the edge of the can, but not inserted into it, as this can cause it to melt.

    • 7

      Check on the steel regularly until it is red hot. At this time, remove it from the coffee can with some tongs and shape it as you like by striking it with a hammer against an anvil. Place it back into the forge whenever the red hue diminishes.


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