Blacksmith Projects

What constitutes a blacksmith project? The answer is that just about everything a blacksmith makes is a “project.”

A hobbyist or amateur Blacksmiths project can consist of anything from making simple nails to small tools for use in the house or decorative items such as metal coasters or candle stands.

The forge shop will produce commissioned forge metal object that can range from door knobs to hat stands to iron gates, decorative grills and architectural fittings.

A large commercial or industrial sized forge shop will produce machine and automobile parts, oil drilling equipment, aircraft and jet engine components and a vast range of other items.

The blacksmith artist will use his blacksmithing skills to produce works of art or decorative items that can range from small decorations pieces, architectural embellishments or busts and large outdoor sculptures.

All of these qualify as Blacksmith projects. But what does the blacksmith have to know and do to execute them? There is a lot more that goes on besides coming up with an idea and then make that idea out of metal. Here is just a partial list of what the blacksmith needs to know to be able to execute a project successfully.

· Of course, he must be an expert in the art for forging and shaping metal
* This person needs to be just as good as business man as he does a blacksmith because all of those skills are needed to run a successful shop. While the profitability aspect does not directly apply to the amateur blacksmith, understanding the economics of the trade will ensure that the hobby does not involve more expenditure than it should.
· He must know what equipment he should keep available and what kinds of projects he can undertake with the materials he has. If a project requires the procurement of additional equipment he must be able to judge the cost effectiveness of the purchase and the long term utilization of the equipment.
· He must be a materials manager and ensure that all the fuel he needs for the forge and metal the has to work with are available when he needs them
· He must be able to provide estimate of cost, time and materials for any projects he undertakes with the knowledge that his reputation depends on his being able to meet these commitments.
· He must be able to perform the basic maintenance of his equipment himself and also know when to call in experts for repairs that are beyond his abilities.
· He needs to b able to sketch and if necessary, prepare detailed drawings of the project he is planning to undertake to ensure that the finished work meets the required specifications.
· A blacksmith needs to be a good record keeper and have details of all the projects he has done, either in a digital or hard copy form. This is required not only for accounting and audit purposes, but also to provide a prospective client with an assurance that the blacksmith will be able to undertake the proposed work.

These are just a few examples of the things a Blacksmith needs to be aware of and do to enable him to execute projects successfully. The final project in its complete form is just one of the very last steps in a line of a lot of complex strategy and planning.

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Medieval Blacksmiths

Medieval Blacksmiths has as much influence on shaping the age they lived in as they did on the metals they worked on. Medieval Europe was the time of the first great advancements in science and technology and new practices in farming, fabrication, construction and fighting were constantly being introduced. If you can imagine, its the blacksmith that made all of this possible.

You will find that the very first medieval blacksmiths were only part time metal workers and had other full time jobs. In small settlements scattered all over the continent, a person with the right physique was chosen, or volunteered, to do his best in heating and shaping iron to meet the needs of the community her lived in. This was part time work to be done only when the primary duties were completed. However, as the part time iron worker’s skills kept improving, the demand for these goods also grew and so producing and selling metal work became a profitable profession.

As the settlements grew in size and more blacksmiths set up shop, the first guilds came into being. There guilds where more than just trade unions. They set the basics standards that the blacksmiths would work to and allowed the sharing of knowledge among the members. Although most tradesmen guilds of the time were secretive, the blacksmiths guilds were more so than most because theirs was a trade that not everyone could undertake and which also required specialized knowledge which was kept closely guarded. This gave the medieval blacksmith an important and powerful position in the society of the times. The Blacksmith in the medieval time had a lot of influence and were treated very well because no one wanted to get on the bad side of a blacksmith or else the next day is sword may be bending or his nails aren't holding up.

The guilds adopted the apprentice approach to teaching young men the trade. Boy of 15 or so would be apprenticed to a master blacksmith and would live with him as part student and part servant. The apprentice would do all the cleaning and menial chores in both the forge and, if need be, in the blacksmith’s home. The forge quickly became this person's home and they would eat, sleep, and work in the forge and also maintain its clean state. Initially he would just observe the master blacksmith at work but slowly, as time passed would be allowed to participate in minor aspects of the forging process until such time as he could perform simple blacksmith jobs on his own. Once the master blacksmith was confident of the apprentice’ skills, he would be given more complex work to do, always under the supervision of his master, until such time as the master was satisfied that the apprentice had learned all that the master could teach, at which time he was allowed to go forth and set up his own forge.

The blacksmith was an important member of society and in times of civil unrest or war was allowed to live and work within the premises of the local castle, which was the most secure place. The army needed it armaments and having their blacksmiths captured or killed by the enemy meant that the army’s ability to fight was severely limited. Blacksmithing was not a glamorous profession in medieval times unlike the writer, artist or knight; but his contribution to the society he lived in was as much, if not more, than those to whom he supplied his goods.

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Classes for Blacksmiths

With blacksmithing returning to popularity both as a trade and a hobby, a vast variety of classes and courses are now available to teach the would be blacksmith both the basics of the art as well as the finer more advanced aspects. Classes are held both in real time at blacksmith schools and also online. There are also a lot of good books that teach the art of blacksmithing. While all these options have their advantages, Blacksmiths is one of the most hands on of all trades and the best option for most people is to attend a proper blacksmith school with real time learning and practical demonstrations and training.

What ever the type of blacksmith classes you opt for; there are some basic issues that a good course should offer. Given below are some key issues which a Blacksmith training course should cover.

· The theory and fundamentals of the trade
· The history of blacksmithing
· Understanding metal – the qualities and suitability of various metals and alloys for forging
· Safety and health concerns
· Different types of forges and which one is best for which applications
· The basics of heating metal
· Heat treatment of metals
* Classes on Hammering Techniques are usually combined as well with instruction on all of the different kinds of hammers
· Hot and cold cutting of metal
· Drawing out  and drawing down metals
· Spreading
· Using a swage block
· Using a punch
· Twisting and wrapping of forged stock
· Tapering
· Twisting, reverse twisting and upsetting
· Using Oxy/Acetylene torches
· The art of scroll making
· Welding
· Grinding and surface preparation
· Chain and ring making
· Tong making
· Drifting and slitting bar stock
· Collars and collar stock
· Options for steel finishing
· Using various forging techniques on the same piece
· Practical work in the form of fabricating items such as candle stands, door knockers vases. The kind of practical work will depend on what specific aspect of blacksmithing the course is teaching.

The exact nature of the syllabus will vary from course to course and varying degrees of importance will be given to specific aspects of Blacksmithing , depending on the focus of the classes. In what detail the various aspects of forging are covered will depend on the duration of the course.  What ever the course duration it is important that the classes should contain not just theory but also practical demonstrations and hands on training for the student. Just as the canvas artist needs a feel for the bush and colors he is working with, the blacksmith needs to have a “feel” for the metal he is using and this can only come from hands on experience.

In order to get to the end results, Blacksmiths are like artists, they all use different techniques and skills to make the same final product. What is taught in a class may be a good way, but it need not necessarily be the only way. A student blacksmith should do as much study on his own as possible and understand the various options in metal working that are available to him. Joining online discussion groups and chat forums will allow the student to exchange ideas with others and broaden his horizon.

Blacksmithing classes are the best way to learn the art. But education doesn’t stop there.

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Blacksmith Supplies

It is a common misconception that a Blacksmith relies on his muscles, a forge and a hammer to create his products. The modern blacksmith is a high tech artisan who uses a variety of sophisticated and complex tools and equipment to produce intricate works of metal.  The modern forge shop is a sophisticated manufacturing unit where the old blacksmith in his leather apron and heavy hammer would feel out of place. Among the supplies available to the modern blacksmith are:

· Forges. While many blacksmiths prefer to make their own traditional coal coke fired forges, a range of traditionally fueled and gas or electric forges are available off the shelf. Besides standard designs n a variety of sizes, special forges for the manufacture of specific items, like a knife forge, are also available.
· Anvils. A range of anvils in a variety of sizes and shapes, designed for use in the creation of specific shapes are available. Using different shape specific anvils to create the desired shapes can both reduce the amount of work required in shaping as well as provide for better accuracy and fineness of finish.
· Tongs. In the case of tongs, one size does not fit all. One of the most important tools are a blacksmiths tongs, and these tongs come in a wide variety of shapes and gripping heads so the blacksmith can choose the exact tong to fit what shape of metal he is working with that very day.
· Hand Hammers. Different sizes of hammers with variously shaped heads are available for the efficient and accurate creation of shapes. Most Blacksmith will have a number of hammers to use depending on what they are trying to achieve. Just like you have tools to help you get certain finishes on your walls at home, there are special finishing hammers that blacksmiths use to finish the metals and create a texture or wood grain look on the metal.
· Power Hammers. Besides the huge industrial size power hammers used in large factories, smaller power hammers of weights ranging from 25 to 500 pounds and above are available for the individual or artist blacksmith.
· Shaping and Cutting Tools. A modern Blacksmiths supplies include a variety of shaping swages, punches and chisels which will reduce the time taken in the production process.
* There should always be Safety Equipment. Working with hot metal can be dangerous and a good forge shop will be sully equipped with all the required safety supplies. These will include gloves, helmets, goggles and other protective equipment. Every blacksmith should know this but since we are working with hot metal, fire, etc there needs to be at least a fire extinguisher in every shop if not a sprinkler system. And, as in any manufacturing unit, a first aid box should always be available.
· Besides the supplies listed here, the modern blacksmith has the option of using painting, welding and a variety of other equipment, depending on what type of work he is doing.

The first blacksmiths often used their shops to make the tools they needed. While some still do this, there are a vast number of companies today that are dedicated to providing the modern blacksmith all the supplies he needs, from the simplest hammers to the most complex electronically controlled hammers and forges to allow him to use state of the art supplies to produce state of the art products.

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Plans for a Blacksmith Forge

The efficiency of a forge shop is, to a large extent, dictated by how well it is laid out. The movement of heavy metal, handling heated ingots, hammering and quenching are all heavy work, even with the latest equipment. A well laid out blacksmith’s shop will keep these factors in mind when it is planned.

The heart of a blacksmith’s shop is the forge itself. If you are looking at a forge that is soley for coal, you may want to note that a coal forge is 100% designed around the heart of the fire. This is the area of maximum heat whose shape can be adjusted, by shifting the burning coals, to suit the needs of the metal being heated. If you look at the fire, its important to think about where the heart of the fire will be because the heart of the fire needs to be the same height as the top of the forge. If it is lower, the Blacksmith will not be able to pass the metal to be heated through the center of the hottest part of the fire. If it is too high, that is above the level of the forge itself, not only will there be heat loss leading to longer heating times for the metal, but that will also be a danger of burning coals falling out of the forge. Your forge needs to be able to handle the biggest pieces of metal that you will be working with so you will not have to bend them in order to heat them. If the forge is too small, Blacksmithing are often forced to build extra large fires to generate more radiant heat to reach the metal that cannot be placed directly in contact with the fire because of its large size. This wastes large amounts of fuel and also requires more air to be pumped into the forge to maintain the heat and blow it towards the metal. And, of course, this is much slower that direct contact heating.

A well planned forge should match the height of the Blacksmithing . If it is too high the blacksmith will have to keep his arms raised while working which can lead to back problems over time. Too low and the blacksmith is constantly bending over the forge which not only will also cause back problems but will allow the heat from the forge to hit him much more than it otherwise would. The ideal height should be somewhere just above the waist level, but this will vary depending on the blacksmiths personal choice. As a general rule the forge height is kept the same as that of the anvil.

The positioning of the air blower is also an important part of the forge plan. Too near and the motor could be affect by the heat. Too far and there will be a pressure loss. Always try and keep the pipe from the blower to the forge straight as bends will reduce the airflow. If the layout of the forge shop requires the blower to be placed in a position where the pipe needs a bend, this should be as gentle a curve as possible.

The forge should be located in such a position that it is easily accessible for cleaning and ash removal. As you can imagine, the forge is a place that gets extremely hot so its good to remember that your forge shop needs to have as good of ventaliation as possible.

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Blacksmith Plans and Planning

To be able to produce a finished work that is either to a commission specifications or which a sellable, the Blacksmiths needs to be more than just an expert metal worker. Of course his skills are important in the quality and value of the finished product, but to be able to work to his best and be sure that he is making a profit on the project, the blacksmith needs to be able to plan his work and expenses. If the Blacksmiths is producing works for sale he needs to:
· Know what are the market rates for equivalent goods
· Ensure that he can match these rates while making a profit for himself.
· Plan on what will make his product unique so that it stands out and attracts customers.
It is the second of these issues that is the most complex and requires a certain amount of both technical and business knowledge.  What is given below in regard to blacksmith plans for commissioned projects will also apply in this case. Commissioned projects are much more complex and require careful planning before they are quoted for and executed. Before undertaking any commissioned project the Blacksmith should ensure that he has planned for taking care of the following issues.

· Study the project in carefully. The devil is always in the details. A slight misreading of the metal specifications or the dimensions will not only cause you to offer a wrong quote, but, if the quote is accepted, cause the final product, on which you have spent so much time, effort and money, to be rejected.
* The input of materials is one of those costs that you need to be very familar with as if you are wrong, this can throw off your bid or even if its a long term project prices can go up on your materials. Many clients may resist this, but you can tell them that you will show proof of escalation, if any, and this will not be add your profits.
· Estimate the time you will require for the project. Your time is valuable and every hour spent on the project which is not charged for is a loss. You could have done something profitable in that period. Its best to always have in mind your competition because that is who you will be quoting against and you will need to keep your time frames as tight as possible.
· Plan your around your other work and projects, adjusting them if needed and if possible, to ensure that you are able to meet the deadline you have offered or the client has demanded.
· If the project involves any work that you cannot do yourself but have to sub contract, ensure that your planning includes both the cost and time required for the sub contracted work.
· Depending on the type of project, make detailed drawings or diagrams and have these approved by the client so that there is no misunderstanding of what the finished product will be or will look like.
· Prepare your own time chart for completing the project with stage wise milestones so you are able to ensure that your work is progressing on schedule.

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Blacksmithing the Colonial Way

Although the US became independent of Britain in 1776, the country’s dependence on Britain and Europe for the goods needed to build the new country remained. For many years all the mechanical equipment the country needed was imported. With the beginning of the industrial revolution in Britain, the sophistication of the machinery began to increase and so did the cost. Whether the increased costs of this machinery was justified or just a case of a near monopoly supplier using its position to charge exorbitant process is still being debated today. After some time, it became quite apparent that the costs of bringing equipment in were much more than what it could be build for domestically. People were almost forced into manufacturing domestically because they couldn't get enough supplies from overseas. There was a big changing of the times because things that were soley imported now were starting to be made by local craftsmen. The range of products was vast, from furniture to glass, leather goods, gunpowder to sewing needles and wagon wheels and much more.

The wealthy tended to look down on such craftsmen as being socially inferior to them and none suffered more from this than the Blacksmith whose forge was hot, dirty, sweaty and full of smoke and soot. The blacksmith himself would usually be covered with the by products of his trade. And yet, the blacksmith was also the most important man in the village. His was an art that not everyone was strong enough to undertake or had the aptitude for. But every other craftsman depended on the blacksmith to provide the tools that were needs for the other crafts to develop.

The Colonial blacksmith’s job revolved around creating and repairing iron tools and implements that were needed in farming, construction and engineering. From ploughs to door hinges to gears and armaments, there was no field of colonial activity where he did not play a part. Becoming a Blacksmiths in colonial times was not easy. If you had to venture out on your own, you first had to go through several years of training and practice under a skilled blacksmith until you were ready. A boy usually became an apprentice at the age of 14 or 15 and continue with the apprenticeship until he reached the age of 20 to 22. The apprentice lived in the forge shop and was responsible for it upkeep, cleanliness, lighting the fires each day and all the other chores. As time passed he would begin to help the master blacksmith in minor metal work and as his skills increased he would be given larger roles until such time as he was able to undertake large and complex projects on his own, at which time his apprenticeship was considered to be over.

The colonial Blacksmithing was part of the expansion into and settlement of the interiors of the country. As people started to spread out the need for more blacksmiths came about because every settlement needed a blacksmith to do every day repairs. As the settlements grew and more blacksmith set up shop, they diversified their trade from manufacturing the tools of survival to making items of domestic use and for decoration. Relics of colonial blacksmith work show impressive degrees of fine details and adornment.

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