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Old 01-20-2015, 08:08 PM
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Default today's forge work

I have to build a small stair rail out of hammered balusters. The customer wanted balusters from king that were hammered square bar, so I bid it using them. Wouldn't you know, they don't have any in stock, nor do they have lengths of bar. It is also on a tight timeline, so no time to wait.
So I hammered them out this afternoon. 10 batches of 6, 4 heats per balusters.


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Last one, hammered, squared back up and straightened




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Pile of balusters growing on the floor.


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I used my 50# pneumatic hammer to texture. 7 strokes per divot, rotate 90, 7 strokes, etc. put them on the anvil to square the bars back up by hand, then, straighten them as I go.
I know Jen would have done them all by hand with an 8# hammer, but she is nuts, so I use a power hammer!
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Last edited by Walker; 01-20-2015 at 08:15 PM.
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Old 01-21-2015, 12:36 AM
doubleD doubleD is offline
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That was a lot more work for your project. It sounds like by you doing the balusters you will make your "timeline" but will this keep you in your project budget?
And they turned out nice looking!!
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Old 01-21-2015, 02:21 AM
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You think that's nuts, I saw a guy in a local shop here doing hammered corner divots on 19 mm square bar for hand rails and fences by hand and cold.

I couldn't believe it. Just shook my head and walked away.... Another one of the 101,000 things I've seen here that leave shaking my head and wondering why they squandered the 2000 year head start they had on Western civilization.
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Old 01-21-2015, 07:21 AM
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Quote:
Originally Posted by Walker View Post
I know Jen would have done them all by hand with an 8# hammer, but she is nuts, so I use a power hammer!
My friend you got me all wrong.. I would have passed on the job... What size are the bars?

Actually I owned a 200lbs Fairbanks hammer which was awesome but never got it setup so I could use it on a regular basis (stationed outside) and then sold it about a year before I moved..

My next hammer will be a hydraulic forge press (modify my 50ton shop press)..

When I read the post and saw the rod on the anvil I was crying " Say it aint so".. Then I read about the power hammer.. Phoooo.. I was cringing for you..

I'm modern in an old fashion kind of way..

The bars look great.. Quality as always..
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Old 01-21-2015, 07:39 AM
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Is that forge using Venturi effect or is there a blower of some sort? If so on either case, what PSI propane you running around?
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Old 01-21-2015, 08:38 AM
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Default Old memories

Quote:
Originally Posted by Walker View Post
I have to build a small stair rail out of hammered balusters. The customer wanted balusters from king that were hammered square bar, so I bid it using them. Wouldn't you know, they don't have any in stock, nor do they have lengths of bar. It is also on a tight timeline, so no time to wait.
So I hammered them out this afternoon. 10 batches of 6, 4 heats per balusters.


Attachment 121516

Last one, hammered, squared back up and straightened


Attachment 121518

Pile of balusters growing on the floor.


Attachment 121519

I used my 50# pneumatic hammer to texture. 7 strokes per divot, rotate 90, 7 strokes, etc. put them on the anvil to square the bars back up by hand, then, straighten them as I go.
I know Jen would have done them all by hand with an 8# hammer, but she is nuts, so I use a power hammer!
This brings back old memories , my first job out of high school in the late sixties , I worked for Henderson Ornamental Iron , in Lansing , Il , they made custom railings , I used to have to make balusters , they had a homemade machine to twist them , I still remember 3 1/2 twists , made a ga-jillion of them , don't miss that job !
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Old 01-21-2015, 08:56 AM
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The bars are 5/8". The forge i made years ago. It has undergone many changes through time. I have put many burners in it, and tried them at every angle in every position. As of right now, they are atmospheric "ron Riel" style burners that point straight down. I have tried them with a blower, and while it is a bit hotter, the scale develops on the pieces at an alarmingly fast rate. I am running the lp at about 7-15 psi.
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Old 01-21-2015, 01:51 PM
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Walker

Do you dislike the Reil burners for some reason?

I know very little bout propane forge burners past the very basics - they mix fuel and air somehow....
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Old 01-21-2015, 08:50 PM
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Originally Posted by camdigger View Post
Walker

Do you dislike the Reil burners for some reason?

I know very little bout propane forge burners past the very basics - they mix fuel and air somehow....
No, they work just fine. I just do not like forced air on them because of the added scale. The reil burners are easy to make and tune, cheap, and burn plenty hot without forced air.
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Old 01-21-2015, 09:39 PM
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Quote:
Originally Posted by camdigger View Post
Another one of the 101,000 things I've seen here that leave shaking my head and wondering why they squandered the 2000 year head start they had on Western civilization.
Cam, its called Islam, that's why.
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