Moving Metal Magazine
Moving Metal Magazine is a bimonthly electronic magazine designed to offer content for beginner, intermediate and experienced blacksmiths; and, to join together a worldwide group of craftspeople. We will feature the smiths you know and some you may not. In addition to these featues, we will publish news, articles and features about events, associations, how-tos, and a wide variety of information. Moving Metal seeks to support the community of blacksmiths worldwide who are keeping and growing a craft that is one of human society’s earliest occupations. Editorial and promotional content will entertain, inform, educate and promote on behalf of this community. Looking to be good stewards of the planet, Moving Metal will be published in electronic form only. That also means you can take it with you on your mobile device wherever you go. Content submissions are welcome with the right of final editing for style, tone, voice and length by the Moving Metal team. Editorial and graphic content contained in each issue may not be used in any form, printed or ditial, without the permission of the editor and only with attribution. Editor: Dan Grubbs Columnists: Brian Brazeal Ric Billy Salyers Contact: Moving Metal Magazine 13605 Jesse James Farm Rd. Kearney, Missouri 64060 USA 816-729-4422 movingmetalmagazine@gmail.com Instagram MeWe Facebook
Photo: J.MT Photography
Table of contents with photos appears on this page
608,000 followers. Be sure to read the profile story about Torbjörn Åhman and get a more detailed picture of the man who rarely speaks in his videos. Young smiths will play an important role in Moving Metal. Not only in content but in making their contributions and creating a sustainable craft into the future. We have two to introduce you to in this issue. Brandon Lee Dearing joins us to write about his start in the craft and movement into architectural blacksmithing that he and his dad have integrated into their family business. Living on their 45 acres the Dearings produce some stunning architectural elements that feature their iron work.
From the Editor Welcome to the inaugural issue of Moving Metal Magazine. As our masthead describes, our purpose is to join together a worldwide group of craftspeople to help form a community. We hope each issue gives you something to take away for your own practice, whether you’re a beginning hobbyist or a seasoned professional. Moving Metal is not setting out to supplant or replace existing publications that many have worked on for decades. We salute those efforts and welcome collaboration from them. The national associations and many state or chapter affiliates all work hard to help their members. I am happy to be a member of the Blacksmith’s Association of Missouri. We want to be part of that same tide that raises all boats. In the spirit of unity, ABANA Executive Director Janie Grela highlights the mission and goals for the association in this first issue. She also paints a picture for the future that includes a new permanent home for ABANA. To use the vernacular, I am stoaked to offer our readers regular contributions from renowned blacksmith Brian Brazeal. In his column, “The Master’s Realm,” Brazeal will bring us his expertise in word and photo. This issue he will show his approach to making tongs. You can see our cover story features a craftsman that many know because of his popular YouTube channel. Last time we checked, he had more than
Speaking of young smiths, how about the artful work of Savannah Taylor? Like many, Savannah was introduced to blacksmithing as a young girl and set herself on a course to becoming a blacksmith. Still in high school, we know she will take her work to a whole new level as she progresses in her skills. A self-motivated girl, she’s even milling the wood to build her own shop. Our publication wouldn’t be complete without the contribution from Forged in Fire champions Billy Salyers and Derek Melton. Billy will bring us his views on how someone can affordably enter the craft of bladesmithing. His meteoric rise in the bladesmithing world is a great story. Induction heaters are growing in popularity, so be sure to check out Derek Melton’s primer on induction heaters. You’ll learn a few things. In our regular column we lightheartedly call “Fighting the Dragon,” Ric Michaelson surveyed a number of smiths and he brings you some of their top safety concerns. Blacksmithing is not without risks, so keeping an eye on safety in your shop is always worth talking about. Many blacksmiths are people of faith. Moving Metal won’t be bashful or restrict these contributors or those featured on our pages from expressing themslves in such a way. Each issue won’t be perfect and it won’t be without disagreement. Blacksmiths are passionate people, and that’s a good thing. Keep your passion strong and the craft will live on.
Fighting the Dra Moving Metal Magazine offers some insights on safety around the forge and in the shop.
by Ric M
agon
Michaelson
d e r l u t a t Fea of Me r e v Mo
Swedish blacksmith
Torbjörn Åhman
‘I think the passion is in
Moving Metal recently connected with the famous YouTuber blacksmith, Torbjörn Åhman, the Thunder Bear himself. He shared how he got his start and his thoughts about his path as a blacksmith.
MM: When people watch your videos, many think you must have a long history in blacksmithing. Can you tell the story of when and what got you started in blacksmithing and what motivated you to pursue the craft?
forge and started some simple projects, and suddenly I was hooked again.
Åhman: To begin with I have always had a strong creative side. I love to build and create things, whatever it may be.
Åhman: I’m not sure. I think the passion is in the process of making. To see if you’re able to make what you set up to do, and figure out a way to move forward. Solving problems is part of the fun but also a challenge and it can be frustrating at times when you don’t know how to do something and you realize you just need to dive in and see if it works.
My mother is an archeologist and through the years she has attended several courses in experimental archeology, to get a deeper understanding for some of her work. At one point, when I was 15
MM: You clearly have a passion for what you are doing in your shops, where do you think that passion comes from?
n the process of making.’ years old, she brought me with her on a week-long class in ancient iron making. There we learned how to make charcoal, roast bog ore and smelt this ore in small bloomery furnaces. Alongside we also got a chance to try blacksmithing, making simple things like hooks and door catches. This is where my interest in blacksmithing first started. I bought an anvil and tinkered a bit in my father’s back yard, but then school and other things became more important and the anvil was put aside for many years. My partner and I decided we watned to move to a place where we had space for a workshop. I brought home the anvil from my mother’s house, who was tired of it sitting in her cellar. I built a
MM: You’ve written that Otto Samuelsson was one of the first smiths that taught you. What were the key things you took away from Mr. Samuelsson back then? Åhman: That was a short class, but I remember I realized how important it was to think ahead, and have a plan for what to do with your next heat. MM: In other artforms, people can point to a style of an artist’s work. Can you describe what you think your style is for your projects? Åhman: I don’t think I have a particular style, but I like things to be functional first. In many cases the process or the nature of the material is giving you the design. Most traditional styles comes from this
A sense of humor is a valued trait for blacksmiths. Certainly something Åhman demonstrates in his videos. I think. That said I also get inspired by the work of other craftsmen and that can probably shine through at times. MM: I think you moved your family onto a property in 2008 in _________, Sweden, and among other things built a greenhouse and workshops. What was your motivation to move? Åhman: The motivation was to get our own place with a garden and a peaceful place for kids to grow up. The choice was easy since it belonged to my partner’s grandmother. She and I took it over and renovated the house before moving in. MM: It’s clear you enjoy what you do on your YouTube channel. And, congratulations for surpassing 608,000 subscribers – a significant achievement. You provide your audience with a wide variety of projects interrupted by scenes from around your homestead. How do you go about picking a project
you want to forge that you will feature on your YT channel? Åhman: It’s not so easy to answer. I don’t have a great master plan. It can be that I want to try something that I never have done before, maybe it involves a technique new to me. Sometimes people ask me to make something specific, and if it feels right I go ahead. Sometimes I try to make something seasonal, like for Halloween or Christmas. For the most part something just pops up in my head and wheels start spinning. It can be frustrating at times to figure out a new project, but if I can’t think of something I have a pretty long list of things in my notebook. MM: It seems building relationships with other YouTube blacksmiths is a good way to grow an audience. Which YouTube channels do you watch and who would you like to connect with going forward? Any future collaborations?
Åhman: The collaborations I have done so far were mostly to show my support and having a fun time, not to grow my audience. For a smaller channel it can probably be a good thing. I follow most of the smiths your readers follow, but I’m struggling to keep up and watch all their videos. Here are a few: Alec Steele - I have been following him since he was 13 I think. Mark Aspery - Huge source of inspiration. Great teacher and fun to watch and read. I have his books. Black Bear Forge - Also a comprehensive source of inspiration and information for anyone interested in the craft with step-by-step instructions for most of his projects. Brian Brazeal - I was early on very influenced by his work, especially the techniques he teaches when hand forging blacksmithing tools. I’m glad to see him contributing to Moving Metal Magazine. Some others are Gary Huston, Joey van der Steeg, Joshua De Lisle, Big Dog Forge and Daniel Moss who all have great channels. There are so many talented smiths and craftspeople out there. I hesitate to pick anyone in particular. I look up to anyone who has made something that triggers my mind. When I see something beautiful, my first thought is almost always - how did they do that or what processes were used to reach that final piece? Looking at old ironwork can be very inspiring and also bring up a lot of questions about how things were made. If we could go back in time, I wonder what we could learn from the long-gone masters, like Samuel Yellin or even the local village blacksmiths. Much of the know-how and knowledge was never passed on, which is sad. I don’t have any planned collaborations, but I am open for suggestions. MM: Why do you stick with coal forging?
How do you pronounce his name? >> launch video Åhman: I think the coal forge is the most versatile. You can heat both small and reasonably large areas. You can isolate a heat to a specific part and you can chose the size of the fire to a degree. I also have an experimental oil-fired forge that is similar to a gas forge. I use it sometimes when heating larger stock or have several pieces going at the same time. Propane gas is pretty expensive here in Sweden, and I don’t quite like the safety issues involved with large quantities of gas in my shop. MM: Most of our readers will not know what you do for a living. Could you tell us what your job is? Åhman: For the last three years or so, making content for my channel has been my job. It does not generate a huge amount of money but enough to let me focus on new projects. Previously, for almost 20 years, I worked with 3D computer graphics, doing visualization, animation, game design, and photorealistic product imagery. All very creative but almost everything you make never leaves the virtual world which is a big contrast to crafting something with your hands. I do miss the undo-button from time to time though. MM: What projects are you considering in the near future? Are you taking commissions? Åhman: I’m currently upgrading my air hammer with a proper lubrication system. It was missing when I got the hammer. It will probably not rank as a blockbuster video, but for many viewers it doesn’t really matter what I do, they like to follow along. After that I will think of something new. In general I don’t commit to commissions since I like to focus on new videos instead of making stuff for sale. But if the request involves something I
like to make, I might. MM: Can you give us a rundown of the machines and equipment you have in your shop, including anything you know about your anvil? Åhman: At this point I’m using: Bêché 75kg air hammer Abno 25kg mechanical spring hammer Arboga drill press Aldell bench/post grinder Kemppi MIG welder ESAB MMA welder Shop saw Belt grinder 2”x72” 2 swage blocks 2 post vices 3 Kohlswa anvils Home-built coal forge Oil-fired furnace And just a few hammers and chisels. Most of the equipment is second hand and did not cost me a fortune as some may think. My large 400-pound anvil is an A1 Kohlswa anvil. A1 is their designation for the English pattern style. I bought it from a gentleman who had it sitting in a barn for many years. It originally came from a saw mill where it was used to straighten saw blades apparently. MM: There are a number of hammers in your shop. Can you describe your go to hammer you use for most of your work on projects? Åhman: Yes, you can’t have too many hammers, right? My favorite hammer is an old TOR’s hammer weighing 900g plus the handle. It’s a Swedish style hammer with a pretty narrow peen and a heavily crowned and slightly rounded face. They can still be bought from Hultafors who incorporated TOR’s line of hammers into their production when they bought the company many years ago. I’d like to remind everyone to remember to dress your hammer face. It’s one of the most common mistakes by the beginner when they buy a new hammer. Remove all sharp corners and make it smooth.
MM: For smiths with a bit less experience, can you give us three things you know now that you wish you knew when you started smithing? Åhman: Metal does not always move as you expect it to do at first. It takes a bit of experience to better judge how to tackle a particular problem. So instead of planning out a project from start to finish, with assumptions, go ahead and make a test piece or two. That will teach you how to make a part right. Although I succeed from time to time with a first try, it always goes much better the second or third time I make something. Make notes. It will help you during a project and certainly afterwards when you are asked to make another one. I’m not terribly good at it myself, but my videos could come in handy one day. Don’t underestimate the time you need for a project, and don’t sell anything too cheap. Both will come back and bite you. MM: A few videos show your children in the shop or around the homestead. How early can parents or mentors introduce blacksmithing to kids? In your opinion, how early can actual training begin? Åhman: I don’t think there is a lower limit really. The child needs some strength to swing a hammer naturally, and to move steel you need some weight, so I guess that is the limit here. But you don’t have to forge to learn, just being around and maybe lend a helping hand can spark interest for the craft. MM: Any other thoughts about your blacksmithing that you’d like to share? Åhman: I’m a bit curious about what the future brings us when it comes to fuels and heating. Using coal and gas isn’t really sustainable, although our consumption is minute compared to industrial applications. Maybe we all need to go back and use plain old charcoal. It can be produced with fewer environmental inpact compared to coal and it’s renewable. It’s hot and relatively clean. Induction heating is another possible option and Derek Melton’s article here is informative.
Visit Åhman’s YouTube channel here.
ABANA feature by Ja
anie Grela, president
The M
Brian B
tong m
Master’s Realm
Brazeal shares his expertise and wisdom
making
Getting started by Billy
as a bladesmith Salyers
Savannah Taylor
Blacksmithing gives a path to artistic exp
One of our goals at Moving Metal Magazine is to help grow the craft by featuring young people taking up the hammer. Here we introduce you to teen blacksmith Savannah Taylor. She lives with her parents, and doting dog Darcy, on their 21-acre hobby farm in Statesville, North Carolina. MM: Savannah, you indicated your fascination in blacksmithing began at age 13. How did you get exposed that it captured your attention so? Taylor: I heard about blacksmithing because a few people I knew at the time were getting interested in it. I really wanted to try it because I’ve always loved working with my hands and creating. My parents were very supportive and found a local blacksmith that I could get a couple classes from. MM: Still just 17, many will be surprised at your craftsmanship. Do you think being a teen blacksmith limits you in any way?
first projects you were ready to show the world? Taylor: It was probably around a year till I felt comfortable showing my work. The first projects I was proud of were some towel rings, fire pokers, and other simple items. Looking back I cringe at how some of those projects looked, but it’s pretty cool to be able to see all the progress I’ve made since then. MM: Your work today shows refinement. Did you have a tutor along the way? Taylor: I took a weekend class a few years back that taught some of the basic techniques of blacksmithing. Then later on a friend of mine gave me a knifemaking class. Since then I have not had any other classes, so I’m mostly self taught. There are also a couple local blacksmiths who have helped me out at times with various things. MM: Would you say your Amish background has
North Carolina teen pression Taylor: I’ve found it very difficult at times to keep up with school and still have enough time to keep up with orders. Also, because of my age I’ve had less blacksmithing and life experience, so I feel that limits me sometimes.
MM: Describe early days when you actually began in your small forging area in your backyard. What were your first tools? Your first projects? Taylor: My early set up was a homemade coal forge and a railroad track anvil. My dad built me a small lean-to off of our barn for my first shop. I made a lot of hooks, fire pokers, and some really awful knives. MM: Your Etsy page indicates you worked on your technique and craft until you could proudly call yourself a blacksmith. How long was it before you felt ready to call yourself that? What were those
had any influence on your work? How about your approach to blacksmithing?
Taylor: My family’s Amish background has mainly influenced my work ethic. I’ve always been very inspired by the dedication and hard work the Amish put into their craft. When it comes to blacksmiting, I try to have the same dedication and attention to detail I see in their work. MM: Do you see making blacksmithing as your career or is it more of a side gig for you? Taylor: I think eventually I would like to blacksmith full time, but for the time being it’ll be just a side gig. For now I’m really not sure what I want to do. I’m looking at various options right now, particularly welding. MM: I’ve read a few comments you made in Instagram posts that you are practicing on a given
project. Do you practice a project a lot before you come to a version with which you’re satisfied?
favoring most of the time. Are there any pieces of equipment you’d like to add to your shop?
Taylor: I usually come up with an idea and sketch it out a few different ways. Sometimes the first time I forge it out I’m perfectly happy with it, but then there are times that I make a project a few more times until I like it.
Taylor: My new shop is still a work in progress so there’s a lot I still want to add to it. I’ve slowly collected various tools through the years, and I prefer not to use power tools when I don’t have to. So when it comes to equipment, I don’t have a huge variety of that.
MM: You seem to favor the small ornamental and functional pieces. Is that your sweet spot or do you also forge other items? Taylor: I do particularly love the ornamental and artistic side of blacksmithing, but occasionally I’ll make tools that I need such as tongs, punches, chisels, etc. MM: There is quite an organic feel to your pieces. Is that intentional? Taylor: Yes that’s intentional. I would say my style right now could be described as simple elegance. I love my work to look delicate and beautiful and be functional at the same time. MM: We’re all aware there is a gender disparity in blacksmithing. Does this inspire you, motivate you? Taylor: I honestly don’t think about it very much. I realize there aren’t nearly as many female as male blacksmiths, but I do think more women are getting into the craft than people realize. MM: Do you have any smiths you look up to? Who have been your influences and inspiration? Taylor: I really am inspired and influenced by so many different smiths, but I would say particularly Roy Adams and Joey Van Der Steeg. They’re so incredibly skilled, and I learn a lot just from looking at their work. I also love Jenny Pickford’s work. Her sculptures are beautiful, and I’d love to do work like that at some point. MM: Describe your current shop set up, your key equipment or machines, what hammers you’re
I mainly use cross-peen and ball-peen hammers. Ball-peen hammers are sometimes my favorite for very delicate work. I’d love to have a larger tool collection in general and at some point get a power hammer. MM: You helped fabricate your own coal forge. Describe the design choices and if you would change anything today now that you’ve used it for a while. Taylor: The blacksmith, Scott Beam, who fabricated it actually helped me make most of my design choices. I really didn’t know much about what I wanted. I just knew I needed an upgrade. I chose most of the sizes for it based on the size of Scott’s forge. After using it for a while, there’s still nothing I would want changed on it. It’s pretty much my dream forge! MM: Your forge is solid fuel. Do you have a gas forge in your shop? Taylor:I don’t use a gas forge for anything right now. I really prefer coal because it can reach such high temperatures, and that comes in very handy for forge welding. Even though gas forges are much cleaner I have a lot more fun using coal. MM: Your Instagram description lists the famous Bible verse from Colossians about doing good work enthusiastically. Would you describe yourself as a person of faith? Taylor: Yes I would describe myself as a person of faith. It really plays the biggest role in my life because it affects every area of my life, even my work.
Above: Savanna working with Scott Beam to fabricate her coal forge. Savanna working at her forge and anvil in her shop.
My faith in Jesus is really the most important thing to me in life. MM: I’ve seen a photo of your beautiful Great Pyrenees. Is it performing as an livestock guardian dog on the farm? Can you describe the farm? Taylor: Darcy isn’t really a LGD. My family just loves Great Pyrenees because they’re super friendly and very protective. I live on a small hobby farm. It’s about 21 acres, and we raise goats and sometimes chickens and pigs. We also have a couple horses and pet pot-bellied pigs. MM: What kinds of projects are you hoping to make in your future? Taylor: I want to do some larger scale ornamental work. I’ve actually designed a pretty large sculpture that I hope to get started on sometime this year. I also hope to develop more toolmaking skills. I’ve always wanted to learn how to make hammers. MM: Have you done any collaboration work with other smith? Is there a smith you’d like to collaborate with? Taylor: I’ve really not done any collaboration with any other smiths yet. At some point I really want to collaborate with Billy Salyers (Yellow Rose Forge). Billy makes some of the most beautiful knives I’ve ever seen, so I would absolutely love to work with him.
Similar to the pieces at left, you can find more exapmples of Savannah Taylor’s work on Instagram.
Videos you may have missed
Each issue, Moving Metal Magazine will present six videos that have something of interest for readers that likely have slipped under most people’s radar. If you know of a video others may have not seen and you think is worthy to share, be sure to let us know.
Slowing down a belt grinder by Make Everything
Site fitting a forged gate by Phoenix Forge
Forge a classic hair pin by Survival of the Fittest
Oak leaf hook rack by Oscar Duck
Folsom knot table lamp by Stone County Ironworks
Blacksmith’s treadle hammer (unique) by Jim Cooper
Ad for ABANA’s annual meeting and open house in Pennsylvania
Brandon Lee Dearing welds blacksmithing to family business
I’m a third-generation craftsman. For as long as I can remember, I’ve worked with my hands. My father has a background in construction and drywall that he learned from his father, and in the early 1990s he began refinishing and selling antiques. He launched into antiques full time and from there he developed an eye for old world European furniture and design. He used those skills to start a business reproducing architectural elements patterned after the old-world styles. Instead of taking old wood and refinishing it, he began building new pieces and distressing them to look centuries old. He builds book cases, tables, fireplace mantles and beams for high-end homes around the country. My brothers, sisters and I grew up working summers in his business. I remember when I was six my dad would sit me in his lap in front of the bandsaw and teach me to cut out shapes from the wood. At 14 I was introduced to the world of blacksmithing. Growing up on a farm I was always carrying knives in the woods, I spent hours trying to hone the cutting edges of my blades, only to have them quickly dull after using them. My dad knew of a guy who forged his own blades. He had been blacksmithing since he was eight after a custom knife maker took him under his wing and showed him how to forge. My dad asked this bladesmith if there was a better way for me to sharpen my knives, a better whetstone I could use or a different sharpening technique. He said the main problem was the quality of knives I was using. He offered to teach me how to forge knives from good steel. I showed up at his shop and he introduced me to The majority of heating steel and shaping it with a hammer, as what we do comes well as how to heat treat and temper knives for a much better, sharper, and tougher blade. from being self-
taught. Constantly experimenting with new finishes for our woodwork, or new ways to bend and shape hot metal.
After spending time with him, my dad was inspired to buy a forge and an anvil, and we began thinking of ways to improve the products we offer. It comes naturally in a small business to try and innovate and improve.
We began to incorporate hand-forged iron into the furniture and design elements that we offered. Europe and early America were full of examples of iron forged into design elements. We learned how to forge iron hand rails, fire screens, door pulls, barn door tracks, and iron brackets used to bolt ceiling truss beams. The woodwork and the blacksmithing both work well together. We often forge lag bolts, straps or braces out of iron to help mount our doors, tie our tables together or support our trusses. The majority of what we do comes from being self-taught. Constantly experimenting with new finishes for our woodwork, or new ways to bend and shape hot metal.
I like the idea of combining different materials to help make products that will last generations. So much of our modern culture focuses on quantity rather than quality, speed rather than style. I believe that many people are getting tired of our throw-away society. I think that our culture is starting more and more to look back at the way things used to be done, how things used to be built. In that way I believe that blacksmithing can tell a story. If something is hand forged, no two pieces are exactly alike. And as you swing the hammer, you’re in complete control of how you’d like the project to turn out. You can forge something simple and practical, or test your creativity, twisting and bending and shaping the steel to add decorative flourishes to your work. When I turned 18, I decided to continue working with my hands to help pay my way through college. Early on though I chose to continue working with my hands in the family business and started branching out in selling products of my own in Kansas City. My father and I continue to work together on projects for his business and he helps me with mine. Part of what we want to start doing is offering classes online for how make the things that we do, and help people as they want to start working with their hands and making things around their homes that at the end of the day they can be proud of. Selling a product is one thing, but we also want to inspire the kind of people who would love to be able to build their own fireplace mantle, or their own shutters, or forge their own knife. I enjoy being able to put my mark on something that at the end of the day will stand the test of time. As a Christian and as man I believe in doing anything I’m engaged in to the best of my ability. Often times I’m working on small details that few people would ever notice, highlighting the steel after it’s been forged, distressing the wood so it looks authentically aged, getting a wood glaze to match just right. I continue to work in a variety of different disciplines. People who work with their hands or seek to preserve a time-honored craft, are in my experience a very welcoming community who will take time out of their schedules to help introduce you to their passion if they sense you sincerely want to learn.
I was fortunate to be introduced into woodworking by my father who was already a very established designer and craftsman, often called a Renaissance Man by his clients, I was able to learn the skills of blacksmithing by a world-class bladesmith who’s been forging since he was eight, I was taught leather working from a custom saddle maker who runs a leather shop that he took over from his father-in-law. A few years ago I was introduced to silversmithing and was able to start working with different precious metals. I was able to learn trapping and snaring from one of the best trappers in the country. Just a few decades ago, blacksmithing was considered a dying art. But now this ancient craft and others like it are experiencing a renaissance, with young men and women like myself able innovate and try new things, while at the same time learning from previous generations.
Induction heaters Brushing away the scale of confusion Contributing smith and Forged In Fire champion, Derek Melton, writes to clear some of the confusion around the Chinese-made 15kw machines and to provide some guidance for those looking to add one to their shop.
My first exposure to an induction forge was at the shop of Clay Spencer in 2019. I took a power hammer tooling class in which we used the induction machine to do some of the forging. I was unable to stop thinking about these incredible machines for months afterwards. I don’t pretend to know all there is about the science and technology behind an induction machine, but I can cover the basics. As I understand it, an induction heater uses electromagnetic induction to create friction in the molecules of a conductive material, such as steel. The heater is built with an electronic oscillator that sends high-frequency AC power through the magnet creating a magnetic field into which a steel can be passed. The resistance of the molecules of the steel causes it to heat from inside.
Growing Use These machines have found a spot in some blacksmiths’ shops now because they can quickly and cleanly heat steel to forging (even welding) temperatures without using an externally applied heat source such as coal, propane, natural gas, etc. When I began shopping for an induction heater for forging purposes, I found the process to be a bit confusing. A quick search on eBay showed all kinds of different machines, many with varying numbers of water ports, different paint schemes, and prices that varied to a wide degree. After many questions and a good bit of research, I believe I can say with confidence that the Chinese company LiHua is the primary manufacturer of most of the machines found online. The different colors, number of water ports and the front panels seem to change based on the model year in which they’re made. From what I could gather, it seems that there are many vendors who
buy these machines in bulk for resale. Therefore, an online vendor in 2021 could be selling machines made years ago, which may look different but have the same performance statistics. I also found that the popular U.S. Solid brand of induction heater, is in fact a re-branded, re-painted LiHua LH-15 unit. Based on my experience and the experience of others who have followed my web guide, I think that most of the machines sold online appear to be of similar quality. Prices in 2020 ranged from $600 to $1,100 for what I believe to be the same machine. After doing my initial research I decided to purchase a 15kw 220-volt machine. I watched the sub-$700 models on eBay for a year before I bought mine and during that time, I noticed they would occasionally be unavailable for a time but then later re-stocked with certain vendors. If you don’t want the U.S. Solid price, keep watching eBay or AliExpress for a 15kw induction heater until you see one that you like that fits your budget. My experience buying the machine was painless, it arrived in a wooden shipping crate, well packed with cardboard and foam and with two pre-made (albeit too large) coils. After unpacking, I made slight modifications to my induction heater to meet my own quality and safety standards.
Needed Modifications Many of these units come with dangerously exposed wiring terminals on the back of the machine. On mine, the ground was at the bottom on the outside in the rear, just below the water out ports while the 220-volt terminals were located near the top under an open, hinged lid. I did not like having these wires and terminals carrying 220 volts so exposed and vulnerable, so I added a small junction box with strain relief for the main wire. I then re-routed the ground inside the case and used some good, shrink-fit ring terminals to
attach the wires inside the case. I added a digital aquarium thermometer to monitor the water temperatures in the cooler. I mounted it to the induction heater and can see the water temperature easily while forging. The goal is keeping water temperatures below 130 F in use and to see when the water temp is nearing freezing in winter.
Tubing and Coils If you’re living in a country that does not use metric fittings, you will need to make adapters to change from the 8 MM tubing to ¼-inch tubing and corresponding nuts. This will be the case if you want to make your own coils. I simply made an adapter using short sections of the original 8 MM tubing soldered to ¼-inch adapters. This allows me to use standard, off-the-shelf parts from a local hardware store to make my own coils. These induction heaters require a water-cooling system. Whether that be a turn-key cooling system you buy or one that you build, they absolutely will not function without it. The internals of the induction heater can get very hot, cooling them properly is key to longevity with these machines. A water chiller circulates cooled water through the machine and through the coil to manage the temperature. There are two primary requirements for the water-cooling system: sufficient pressure and a correct temperature range of the coolant. Without adequate water pressure or sufficient cooling, the machine will sound an alarm and shut down. This is a fail-safe to prevent you from damaging your machine. I decided to go the turn-key route and purchased the 110-volt WS-25L water chiller which is a 25-liter tig welding cooler. An induction machine is only as effective as the coils you make for it. The coils should be appropriately sized for the material you are planning to heat. Just as a blacksmith may have dozens of types of tongs for various material, you will soon discover that you will have dozens of types of coils. A general rule of thumb is to make the coils with approximately 5 MM of space between the material being heated and the inside of the coil. Initially, I had trouble getting the material hot enough when trying to heat ½-inch square mild steel bar with the oversized 2½ -3-inch coil that came with my machine. I made my first couple of custom coils by winding ¼ inch copper refrigeration tubing around
Melton’s induction heater setup, front and back, showing modifications with hose and wire arrangements and the 25 liter cooler.
different sizes of pipe. After making the appropriately sized smaller coil, I was able to get a ½-inch bar to a spark-throwing welding heat in less than 30 seconds at full current. Copper coils will last longer with a bit of care. I coat them with Meeco Gasketing Cement and Furnace Sealant. It’s a somewhat sticky substance that dries to a hard, rubber like coating and resists temperatures up to 2,000 F. Having the coil coated with this sealant or a ceramic flexible tubing does not affect the heating capabilities at all and keeps you from making contact with the copper and causing a short, which almost always results in a startling shower of sparks and if done enough, can burn a hole in your copper tubing and allow water to suddenly spray out of the coils. I’ve found that I need to re-coat the coils occasionally as I wear through the coating from being careless with material in the coil. Coils will vary in their effectiveness based on the number of turns and the width between them. I have found that with these 15kw machines, too many turns can cause the machine to fault and not function correctly. For ‘standard’ coils I have found that 3-5 turns appears to work well. There are various other types of coils that can be made to allow the user to not have to pass material through a loop, sometimes these are referred to as “taco” coils, “pancake” coils, etc.
Cost Savings One of the most common concerns that people have when they see these machines is that they believe that they will greatly increase the cost of their electric bill. These machines are only drawing about 35 amps when the machine is engaged to heat material. Since it does that task so quickly, that engagement period is typically very short. I
have not found that my electric consumption has increased to a noticeable degree since moving primarily to induction heating for my work. In a nutshell, I have compared my electric bills over a six-month period between this year and last year and I can see no significant increase in my monthly payments. There may be a $10 or so difference but nothing extreme. I have however, seen a drastic decrease in the amount of propane I have had to buy, so I call that a win. I have found these machines to be extremely effective for forging and after using one for an extended period. I feel safe in saying that, if possible, I will always try to have one in my workshop. It has become a daily use tool and has changed my forging process for many of the products that I make in the shop. You can find an Induction Forge Facebook group.
Launch the Melton Forge Works podcast
Product Review: Smith’s W by Dan Grubbs
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Clothing is not the first thing that comes to people’s mind when they think of tools. But, there’s not much out there that is as hard on clothing as blacksmithing. So, it made sense to offer a review of some carpenter pants that could be your next tool purchase. I’ve been wearing Smith’s Workwear clothing for about three years now with very happy results. I’ll give you a review of their basic carpenter pant that I wear on our homestead for chores and in our workshop. The thing that sets this pant apart from other value brands is the durability for the money. Like most homesteaders, I have my share of Carhart products. I’ve never been displeased with any clothing from Carhart. However, my wife is frugal and made an online purchase of several Smith’s Workwear carpenter pants and I immediately put them through the paces on our 15 acres. Smith’s Workwear is a brand of the American company in Brooklyn, New York, originally known as the Brooklyn Overall Company which began in 1906. Their website indicates they are a family-owned fourth generation company.
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These carpenter pants are cut with plenty of room to move, kneel, bend, sit and other activities normal for an active homestead and shop. Features include a hammer loop, side plier pockets on the outside of the right thigh, deep front pockets and standard back pockets. The pockets are rivet reinforced at the stress points, and all elements are double stitched. The panels of the pants are sewn together with triple stitching. The duck cloth is tightly woven, and its weight is sufficient enough to withstand abrading from the standard scrapes and scuffs that occur on a homestead or in an active workshop. It will protect the wearer’s skin from quite a bit, including welding activity. However, the cotton duck is also light enough to breathe so the wearer does not overheat in warmer temperatures. It’s certainly tougher than denim, yet light enough for a hot shop.
Workwear carpenter pants I’m always bothered by the way leather belts end up with a kink caused from pressure by the top of the back belt loop. Smith’s Workwear not only provides wide belt loops, but also employs two back belt loops about an inch apart on these carpenter pants. This spreads the pressure on the belt and helps provide a more secure cinch while keeping the belt within the waistband.
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A robust brass zipper is another key feature of these carpenter pants. The tab is easily gripped and worked smoothly up and down the teeth. Being brass, they resist corrosion and are more resistant to abrasion from actions around the workshop. I have not had a zipper failure in any way. The waist band is secured with a large brass button grommeted through the material. After about two year’s worth of building projects, care of homestead animals, shop activities and house maintenance I finally did wear through the knees of my first pair. However, I will admit to a lot of kneeling work in limestone gravel in that period. Simple knee patching gives these well-constructed pants extended life. I’ve not had any other part or portion of the pants fail or wear out. Being cotton, there will be some minor shrinkage, much like a pair of denim jeans. They will wrinkle a bit from washing and drying, but wear will relax the material back to normal. Having spent many hard hours in these pants, I can highly recommend them to anyone needing a pair of good shop or work pants. Then, when you factor in the cost, it’s a no brainer. My wife purchased my first three pairs online for less than $20 each. Now I rotate them. Our happy find in these carpenter pants led us to purchase other Smith’s Workwear clothing, such as base later flannel shirts and outer layer flannel shirt-jackets. For a value-type brand, Smith’s Workwear performs like a premium brand with the same stylings that you would come to expect from the popular brand. We’re sold.
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