It doesn't get much easier than this to make yourself a small coal forge (in which you could also use BBQ briquettes or charcoal).
Find a 14" tire rim. This is the type used on emergency tires on new vehicles. The one shown isn't particularly suitable due to the many holes in it. Try to find one which is an enclosed bowl with just the lug nuts and axle holes. (Photo #1) (I use these under pasture salt blocks to keep them off the ground. They last for several years before rusting out.)
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Find a five-gallon metal bucket. Check at places which put on roof coating as some come in them.
For a blower find a small squirrel cage fan. If you cannot find one locally try General Surplus Center at www.surpluscenter.com or by requesting a catalog at 800-488-3407. They currently have a two-speed, 115-volt blower listed as item #16-1266 and a three-speed 12-volt blower listed as item #16-1279. (Photo #2)
Place the blower output flange against the bucket and mark out the air exhaust hole on the bucket. The one shown would require a round hole. For a square vent cut out the hole in the bucket in the form of an X and bend out the flanges. These can then be used to secure the blower to the bucket.
Air flow can also be controlled by putting something, such as a plastic lid, up against the air intake of the blower as shown. The suction will hold it against the air intake.
Turn the tire rim over and weld on some bars across the axle hole. This will keep large pieces of coal from falling in the bucket, yet allow air flow to the fire and ashes to go into the bucket. (Photo #3). Be sure they will be on the bottom of the rim when in use so they don't burn out from the fire. Also cover the lug holes with washers and a bolt.
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Now just set the rim over the bucket so it nestles down in it as shown in the first photo.
For coal, stoker (furnace) coal will work, but will not perform as well as metallurgist-grade coal. If you cannot find it at a coal yard, it is available on eBay-although shipping is costly.
When assembled, there is a trick to starting a coal fire. Wad up three full sheets of newspaper into a tight wad. Light one side and place the wad over the former axle hole. Now turn on your blower enough to have a good blast of air come past the paper, but not enough to blow it out of the bowl. Then place on smaller chunks of coal over the paper to eventually cover it. Once you can see the coal starting to burn, you can add more coal and increase blower speed. After your first fire you will have leftover coke from the previous one to use as starter fuel. (And I have seen experienced blacksmiths take several tries to get a new coal fire going.)
For forge tools just buy a wood burning stove/fireplace shovel from a local source and find about a 24" length of 3/8" or so rod. Put a slight point on one end of the rod and bend about 3" of the other end over. The pointed end can be used to poke around the fire and the bent end used to move fuel around.
If you have a copy of (or can get your local library to obtain a loaner copy), check out the chapter on Metalworking/Blacksmithing in Reader's Digest's Back to Basics: How to Learn and Enjoy Traditional American Skills. This is an overall excellent reference book for a homesteader.
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If you are seeking blacksmithing tools, the best source is now www.ebay.com. Just do a search on blacksmith or go to the category for Collectibles/Tools, Hardware & Locks/Tools/Blacksmithing. Before bidding search what other similar tools have sold for in the past 60 days by doing an Advanced Search on completed items using only the key search word for the tool. Keep in mind shipping costs may be more than the tool itself.
(Personally, I use a propane forge. It is much cleaner, fuel is readily available and, for many jobs, I can be through before a coal fire would even come up to working condition. These are also offered on eBay.)
Shop tips
- You can cut plate steel with a table saw. Find someone with a metal cutting chop saw and offer to buy their blade when it wears down to the size of your table saw (e.g., 10" or 12"). Just offer to pay for a new blade. Mount the metal cutting saw like a wood cutting one, although you may need to add a hub spacer. Don't try to cut all the way through with one pass. Raise the blade just above the table and cut a groove. Then raise a bit higher and deepen the groove. It may take several passes to come to the plate surface. Don't rush it. Always wear safety glasses and good gloves and be mindful you are shooting sparks into sawdust.
- Rather than keeping an extensive supply of bolts on hand, just buy a length of all-thread rod for each size and a box of nuts for that size. When you need a bolt cut the length needed and arc weld on one of the nuts for a bolt head. Put on the nuts before cutting and then back one up to leave a dimple for filling with weld. Use the second nut as a tap to clean up the threads at the cut. These should not be used if the bolt will be under much stress.
