New Coal Forge Build! (pic heavy)

Scratch
Posts: 18
Joined: Mon Aug 10, 2015 8:40 pm

New Coal Forge Build! (pic heavy)

Unread post by Scratch » Mon Nov 06, 2017 6:54 pm

Well I recently finished up my third forge and thought I'd share the build with you all as I think it turned out pretty well. Sorry about all the pics, but everybody like pics right!?!?
Back in about 2007, I built a real nice propane gas forge for my very first forge, and while it worked well, I quickly realized that I needed something that could handle a wider piece. So about a year later, I ended up making a simple coal forge from a wheelbarrow tub and a clothes dryer blower. I figured I'd make something simple, quick and cheap... then when I get more experience and could figure out exactly what I wanted in a forge, I could build one specifically to suit my needs. Well I finally went and did it, and I took pictures too! ... Lots and lots of pictures...

To reminisce... here is a picture of my first gas forge, and also my simple wheelbarrow forge.
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Scratch
Posts: 18
Joined: Mon Aug 10, 2015 8:40 pm

Re: New Coal Forge Build! (pic heavy)

Unread post by Scratch » Mon Nov 06, 2017 6:55 pm

Now, let's get on with the build!
I've always considered the the firepot to be the heart of the forge, so that's what I started with. I have a CNC plasma cutting table so I drew up the firepot in Corel Draw, then cut out the pieces from 1/4" A36 HR steel and welded it up.
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Scratch
Posts: 18
Joined: Mon Aug 10, 2015 8:40 pm

Re: New Coal Forge Build! (pic heavy)

Unread post by Scratch » Mon Nov 06, 2017 6:56 pm

Then I drew up an easy to replace "grate plate" for the bottom of the firpot. I was going to just weld in some bars for the grate, but thought I could easily cut a new one when it gets burnt out, and just drop it in place like this. The extra thickness will help the firpot last longer as well.
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Scratch
Posts: 18
Joined: Mon Aug 10, 2015 8:40 pm

Re: New Coal Forge Build! (pic heavy)

Unread post by Scratch » Mon Nov 06, 2017 6:58 pm

Next I drew up the floor pan and cut it out from 3/16" steel, then drew up the four sides, cut them out, and welded them to the floor pan.
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Scratch
Posts: 18
Joined: Mon Aug 10, 2015 8:40 pm

Re: New Coal Forge Build! (pic heavy)

Unread post by Scratch » Mon Nov 06, 2017 6:58 pm

Then I welded on some legs from 2X2 square tubing, welded some feet on them, and added some wheels on the back legs. The finished floor pan height is 32".
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Scratch
Posts: 18
Joined: Mon Aug 10, 2015 8:40 pm

Re: New Coal Forge Build! (pic heavy)

Unread post by Scratch » Mon Nov 06, 2017 6:59 pm

I tore apart my wheelbarrow forge and used the blower, tuyere, and ash dump from it since it would save time, and it already worked great. I do wish the ash dump was deeper, but I can live with emptying it more often. I also welded on some bracing straps to mount the blower directly to the tuyere.
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Scratch
Posts: 18
Joined: Mon Aug 10, 2015 8:40 pm

Re: New Coal Forge Build! (pic heavy)

Unread post by Scratch » Mon Nov 06, 2017 7:01 pm

I was going to drill and tap some holes in the bottom of the firepot, but I couldn't find my tap and die set, so I figured out which position I wanted the tuyere, drilled some matching holes in the firepot and the flange, then cut the heads off some 3/8" bolts and welded them in place to use as studs instead. I used blue tape to hold the studs upward in place while I plug welded them from the bottom inside of the firepot. Worked great!
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Scratch
Posts: 18
Joined: Mon Aug 10, 2015 8:40 pm

Re: New Coal Forge Build! (pic heavy)

Unread post by Scratch » Mon Nov 06, 2017 7:02 pm

Here you can see a close up of them bolted together, a complete shot of my firepot/tuyere/blower/ash dump assembly, and finally with it installed under the forge body.
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Scratch
Posts: 18
Joined: Mon Aug 10, 2015 8:40 pm

Re: New Coal Forge Build! (pic heavy)

Unread post by Scratch » Mon Nov 06, 2017 7:02 pm

I drew and cut out a piece of 14 guage steel for an air gate, then welded a handle and a stop to it. CNC plasma tables sure are handy!
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Scratch
Posts: 18
Joined: Mon Aug 10, 2015 8:40 pm

Re: New Coal Forge Build! (pic heavy)

Unread post by Scratch » Mon Nov 06, 2017 7:03 pm

I decided to weld on some bars to hold my tongs, shovel, rake, etc... from 3/8" X 1" bar stock. I put them on three sides since I wanted the versability to be able to use it in lots of orientations.
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