Bottom blast coal forge
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The bottom-blast forge

This is a design for the air inlet on a bottom blast forge.
It can be made out of some 50mm or 75mm steel tube, with a wall thickness of at least 2mm.

Health warning:
Pickle with HCl or grind off any zinc galvanizing before attempting to weld!

The top extension should be at least 50mm long.

The bottom extension is to catch ash and clinker that drops through the grid on top. A hinged plate held in place with a coil spring prevents the air blast from escaping.

   
The air blast enters the forge through a grid like this.

Use some 10mm or 12mm thick steel plate. Cut a disk the same diameter as the pipe, mark out 3 slots, each 12mm wide and 12mm apart, drill the ends, and cut through with a angle grinder, clean the slots up with a file

   
Through section of bottom blast forge.

The forge is filled with clay, or refractory cement. The hollow should be between 50 and 100 mm deep, and about 250mm across. The air inlet extends at least 50 mm above the bottom of the forge. This keeps the bottom of the forge from overheating

   
Box construction bottom blast forge

The box may be made out of steel plate, anything thicker than 2.5 mm will work. Legs may be square tube or thick angle iron

The high panel on the left is to keep flying ash off the blower. The cut-outs front and back is useful when one heats long stock. The lip around the edges keeps coal from falling off.

A bracket (not shown) needs to attached to support the blower

   
Round bottom blast forge

For this one might use a truck brake drum or cut of about 300mm from the bottom of a 40 gallon drum.

One might add a panel or shield on one side to protect the blower.

   

Alternatives for for bottom blast forges are legion. Truck bell-housings (the cast iron bowl between the gearbox and the engine) works very well. Plough shares with a steel rim welded on also works.
 You can even use a wooden box if you use a sufficient thickness of fire clay to line it.

If you can't find fire clay, you can substitute it with still wet unbaked clay bricks. Most brickyards will let you have as much as you need for a nominal fee. The wet bricks can be cut with a sturdy blade or with a hacksaw. Make some clay slip (a runny clay paste made by mixing some of the clay with water) and use this to cement the bricks together. Let the bricks dry out for a few days, then make a large wood fire over the whole clay surface. DON'T use any air blast for this first firing. Clean the forge after it has cooled off, fix any cracks that might have formed with some clay slip. Then you can go ahead and light your first coal fire with air blast.

Clean a clay forge out every 5 days of  use, inspect for cracks, fill these up with fire clay, refractory cement or even potters clay after wetting the crack with some water.

Blowers:

Any high volume low pressure fan or blower will work. The best are "squirrel cage" blowers. (Ryobi makes a portable one that can be used as dust extractor or shop vac with a suitable flexi pipe connected to the inlet. To use it as a forge blower, connect the forge to the blower's outlet.

You might find old hand-crank forge blowers at second-hand dealers or even at junk yards. A day spend disassembling, cleaning and oiling the moving parts will be well spend if you do find one of these. You might have to replace the sealing gaskets as well.

 

This page last edited on Saturday, 17 September 2011 
 

 

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