Sunday, July 18, 2010
Tuesday, July 6, 2010
Forge Welding
I was making some crosses last evening in preparation for Market Fair. You can see some shots of these crosses in one of my recent posts here: http://blackforestironworks.blogspot.com/2010/06/beautiful-rustic-cross.html.
These crosses require some welding. There are various techniques for welding (i.e. forge, MIG, Oxy-Acetylene), and I have taken a few classes in the various methods.
These crosses require some welding. There are various techniques for welding (i.e. forge, MIG, Oxy-Acetylene), and I have taken a few classes in the various methods.
This is my Chile Forge "Tabasco" at full burn (~20 psi) ready to weld:
Last night, I forge-welded, which involves scarfing the two ends to be joined (tapering them to thin, flat ends which overlap), heating the metal to immediately below its melting point and using a powder called flux (borax) to impede oxidation and increase the chance that the weld will stick. Once the two ends get to "white-hot" in the forge, the piece comes quickly out of the forge and is hammered together to make the weld.
Monday, July 5, 2010
Reviewing the Day's Work
After an evening in the forge, I often bring my work in to study it and to share it with the family; I often "tweak" it the following day to get it just how I want it.

You can see it was pretty hot out there. The temp went over 90 during the day this day, and most of this week. Even at almost 9PM, it had to be close to 100 degrees out there!
I noticed this one had a slight bend in the tail that made it sit funny and the cup was also tilted, neither of which I could let slide, so I fixed both the next day.
Saturday, July 3, 2010
In the Forge: Scroll Candlestick Holders
Market Fair is July 17th and 18th, and I am getting ready. Today, I was making some scroll candlestick holders:
Friday, July 2, 2010
Tasks
Make MF Inventory - 3 candlestick holders, 3 letter openers, 3 crosses, leaves
Finish ring
Make trivet
Make Tongs
Buy Drill Press
Buy Drill Press
Buy Sander
Make anvil Swage box (from Mark's book)
Make vise stand (from Mark's book)
Scott Forge (Illinois) family tour
Make vise stand (from Mark's book)
Scott Forge (Illinois) family tour
Claude Moore Colonial Farm Market Fair Brochure
Hello Market Fair visitors --
This is shaping up to be a great Fair. Below is a PDF that you can print and post to get the word out about the July Market Fair. Put it up at work, in your neighborhood, anywhere you can think of!
This is shaping up to be a great Fair. Below is a PDF that you can print and post to get the word out about the July Market Fair. Put it up at work, in your neighborhood, anywhere you can think of!
Hope to see you there!
Please see more details at Claude Moore Colonial Farm website at: http://www.1771.org/
Friday, June 25, 2010
Mark Aspery Class: Pass-through Ring
I took an amazing class June 13-19 at Touchstone Center for Crafts in Farmington, Pennsylvania taught by Mark Aspery and his more-than-able assistant, Gerald Boggs. I took a week of vacation and really expanded my craft during my time there. The place was great, with very nice dorms and lots of other artists there to talk and eat meals with and a campfire every night to sit around and talk to other artists. It was very cool.
The class was based around making a pass-through ring to learn about all aspects of joinery. The idea for the class was an inspiration Mark had when he viewed a similar ring in one of Fritz Kuhn's books from the 1920's and was motivated to understand how this was done. He spent the next several months reverse engineering the ring and how to make it as part of the research for his third book, coming in a year or so, that will focus on joinery techniques for the blacksmith.
The ring itself starts with a 1/2 straight bar that forms the ring. There are some relatively complicated mathematics (for me, anyway!) to measure the stretch of the metal and the holes in it as it bends into a ring, so much of the lecture time was focused on this. It was a great growth experience to immerse myself in the details of how something like this is made and the reasons things are done certain ways. The complexity and accuracy inherent in a piece like this required an intense focus and precision to get it right and that also was a good learning opportunity for me. For example, all the holes are punched before assembly and they cannot be off more than 1/16 or the piece will not fit together.
The ring itself starts with a 1/2 straight bar that forms the ring. There are some relatively complicated mathematics (for me, anyway!) to measure the stretch of the metal and the holes in it as it bends into a ring, so much of the lecture time was focused on this. It was a great growth experience to immerse myself in the details of how something like this is made and the reasons things are done certain ways. The complexity and accuracy inherent in a piece like this required an intense focus and precision to get it right and that also was a good learning opportunity for me. For example, all the holes are punched before assembly and they cannot be off more than 1/16 or the piece will not fit together.
Mark's version (pictured on his website at http://www.markaspery.net/) of the pass-through ring:
In the class, we spent the first 3 days making all the necessary tools to make this pass-through ring.
- 1/2" drift
- 9/16" drift
- 9/16" slot punch (tempered)
- 3/4" square drift
- 3/4" slot punch (tempered)
- Fulstum cone
- Hardy base for the cone
- Chainmaker's swage
- 1/2" round hardy bottom tool
For the piece itself, there are two square holes punched in the round bar before it is bent in several stages into a semi-circle (later into the full circle). The square vertical bar comes next and two round holes are punched in it that will eventually allow the ring to pass through those.
There is an interesting lesson in that square piece alone because metal expands when it is hot like most things, so it will essentially be larger when the holes are punched and then shrink as it cools. This has to be taken into consideration when punching the holes, so it is not only the alignment of the holes (where they are on the bar) that must be measured, but also the size of the final hole when it is cool. Essentially the hole has to be slightly larger than the bar passing through it when it is cool (Mark calls is 1/2+) and then punched slightly larger than that (1/2++) to allow for the cooling because it is punched hot. This concept has some interesting implications on your tooling as well, since the tool itself has to be correctly (and accurately) made to one of these three sizes so the hole ends up correct at the end.
Which size should the tool be, you ask? Well, it can't be 1/2" because that is the same size as the bar passing through it and it can't be 1/2+ because the hole must be that size when it is cool (finished) so the ring can safely pass through it. Since the piece will be hot when punched, the tool must be made to punch 1/2++ so the hole can cool (shrink) back to the proper size. We made our punch and drift to make the holes 9/16" and that allows enough space for the ring to pass through even after the shrinking.
So, the class was incredible because we learned and practiced an amazing variety of skills and disciplines just to get to the point where we could consider making the piece. I consider the event a major growth period in my progression as a blacksmith and I am glad I had the opportunity to participate.
Wednesday, June 23, 2010
Sunday, June 13, 2010
A Beautiful, Rustic Cross
I have been working on a cross for a friend who will give it to his father for Father's Day. To make the ring, I got to try out his own forge welding system in my home forge for the first time. It worked, but not without some collateral damage. Unfortunately, I burnt out the bottom part of the forge because I forgot to put the side and bottom armor in (extra floor and sides for exactly this purpose), but it was definitely a learning experience. Yesterday, I put the finishing touches on the cross:
Monday, May 31, 2010
Leaves
I made some leaves recently as one of my first commissions. I think these will make wonderful gifts and my wife and the buyer think they are beautiful, so I will keep making them. I hope to have some more available for the Market Fair in July.
Here is what they look like shaped, but not finished:
Here is the finished product:
Sunday, May 30, 2010
The Tradeoffs of Using Propane or Coal Forges
The main advantage I have found with using propane is that your pieces don't burn up. If you leave a piece in a coal forge for too long there is a risk it will burn up (literally disintegrate and/or fall off), which stinks after you have time invested in a piece. That said, fire management is good skill to know and it is fun to use coal if you are a fire bug like most of us blacksmiths are.
In terms of overall productivity, however, propane is way better because it lights in an instant (no kindling, fussing, clinkers, etc) and your pieces can stay in the fire for long periods without burning up (essential if you are like me and get distracted all the time), so a larger percentage of the time you have available can be spent actually forging rather than futzing with the fire. Its really a personal choice though and everyone is different. Some guys will only use coal and the opposite is also true and everyone has their own set of reasons.
In terms of overall productivity, however, propane is way better because it lights in an instant (no kindling, fussing, clinkers, etc) and your pieces can stay in the fire for long periods without burning up (essential if you are like me and get distracted all the time), so a larger percentage of the time you have available can be spent actually forging rather than futzing with the fire. Its really a personal choice though and everyone is different. Some guys will only use coal and the opposite is also true and everyone has their own set of reasons.
I would think in most cases, propane would work well for beginners because you have less to worry about. Having to manage a fire AND worry about not buring yourself AND also trying to hit the piece while its hot AND trying to make contact in a place and that will actually move metal where you want it to is plenty to think about.
You can always try a coal fire at any time, so there is no hurry to learn that, especially if you have access to a propane forge already. Most guys start with coal because they don't have a propane forge yet and the cost to entry is less. If you are in a neighborhood, though, propane is the only way to go because there is no smoke to disturb the neighbors.
Hope this helps.
Thursday, May 27, 2010
Friday, May 21, 2010
In action at the Market Fair!
This photo was taken by a new friend of ours, Donielle Rininger, and I like it very much. I am completely amazed that she caught the hammer in motion like she did.
At this point, I was at the very beginning of making a nail for a hook they were planning to hang in their home, which happens to be the exact same log cabin as we built. Donielle's husband Michael also happens to be a respected bee expert, which is something we are considering trying, so this photo represents a lot of touch points for all of us.
If you had told me several years ago that my chosen hobby would allow me to meet such interesting people, I never would have believed it, but it is true. Pretty cool stuff!
Sunday, May 16, 2010
Colonial Farm Market Fair: Day 2
Another wonderful day -- many thanks to everyone who came out to see me!
Here, Kelly and I are working on a tenon (which connects into a mortis). It was great to have two of us there because we were able to do things we might not otherwise have been able to do. For example, here I am hammering and Kelly is holding the piece in tongs in one hand and the chisel in tongs in the other.
Sometimes it seems like a blacksmith needs 3 hands! :-)
Sometimes it seems like a blacksmith needs 3 hands! :-)




Saturday, May 15, 2010
Colonial Farm Market Fair: Day 1
My very talented wife setup this table with my pieces for the Fair.

I really enjoy explaining to the guests what I just made and how it all works. The people were great and sometimes the conversation is more enjoyable that making the piece itself!
Sometimes the crowd was smaller than at other times:
I was really fortunate this time to have Kelly Smyth to work with this time. Kelly has an amazing background and had been a professional smith for more than 30 years, so I learned some amazing things from her. One of the best things was her patient lessons on the ins and outs of making mortis and tenon joins. I really got an immersion in those this weekend and it was great to spend time with Kelly.
I really look forward to working with her again in July at the next Market Fair!
I forgot my hardy cutoff on the first day, so this photo shows me using a handheld one, which is significantly harder than the hardy version!
Thursday, May 13, 2010
Countdown to Claude Moore
I started cleaning up my pieces between conference calls and meetings to potentially sell this weekend. And, I am going to start taking orders and selling pieces on the website in the near future. How cool is that?
Monday, May 10, 2010
Sunday, March 14, 2010
Aspery Prep!
I am really excited about my summer blacksmithing adventures! I signed up for a class with my favorite master smith, Mark Aspery at Touchstone in June, so I am in the process now of making it through his first book.
Having met Mark once at last year's BGOV Hammer-in, I know how serious a smith he is and so I want to be prepared to make the most of my week with him! His book is called "Mastering the Fundamentals of Blacksmithing" (http://markaspery.net/www.markaspery.net/Book_1.html) and it is truly an incredible resource.
Having met Mark once at last year's BGOV Hammer-in, I know how serious a smith he is and so I want to be prepared to make the most of my week with him! His book is called "Mastering the Fundamentals of Blacksmithing" (http://markaspery.net/www.markaspery.net/Book_1.html) and it is truly an incredible resource.
I have been going "back to basics" in this book and it has been very fun. I actually understand the beginning chapters now since I have a little more experience and have been focusing on the tapers section first. It is definitely an area that develops skill as you do it.
I love one of the stories in the book, which talks about how Mark learned tapers when he was given his first job as a fledgling smith to make 1000 (yes, I did not mistype this) tapered points from 3/4" bar to use for mooring boats. I have probably made less than 50 real tapers (well, probably more if you include hooks, but my point is still valid) in the entire two years I have been a blacksmith, so I can't imagine how much one can learn doing 1000 of them!
Just scratching the surface here in terms of where I hope to go, but really enjoying it. Thanks, Mark!!
I love one of the stories in the book, which talks about how Mark learned tapers when he was given his first job as a fledgling smith to make 1000 (yes, I did not mistype this) tapered points from 3/4" bar to use for mooring boats. I have probably made less than 50 real tapers (well, probably more if you include hooks, but my point is still valid) in the entire two years I have been a blacksmith, so I can't imagine how much one can learn doing 1000 of them!
Just scratching the surface here in terms of where I hope to go, but really enjoying it. Thanks, Mark!!
Sunday, February 14, 2010
Progress!
I have been making scroll candlestick holders and backscratchers lately to prep for the May Market Fair. My goal will be to learn a lot making the same thing over and over again and also to build up some inventory to sell at the Fair. I plan to have a dozen of each by May. I would also like to have 20-30 hooks done as well, but I haven't really started on those yet.
The last few weeks (through the holiday break) have been big for me in terms of progress. On the backscratchers, I figured out how to make the twist on the handle finally. I started out trying to twist the two ends around each other and then realized it was way easier to bend the piece and then grab the loop to make the twist. That knowledge saved me huge amounts of time and I ended up being able to make one in 30 minutes this week, which pleased me.
I have learned a tremendous amount on the candlestick holders as well. I learned the following things related to the pipe portion of the project:
The last few weeks (through the holiday break) have been big for me in terms of progress. On the backscratchers, I figured out how to make the twist on the handle finally. I started out trying to twist the two ends around each other and then realized it was way easier to bend the piece and then grab the loop to make the twist. That knowledge saved me huge amounts of time and I ended up being able to make one in 30 minutes this week, which pleased me.
I have learned a tremendous amount on the candlestick holders as well. I learned the following things related to the pipe portion of the project:
- Don't cut the pipe with the hardy cut off - the pipe will get smashed and be unusable for the next time
- Cut the pipe with a hacksaw and begin the cut rightat the end of the fullered portion because otherwise you will end up with too much material for the rivet
- Stand on a piece of 4x4 or something else to make yourself taller when hammering the pipe in the fuller in the vise - I did this a few times standing on the ground and I ended up getting way too fatigued and the fuller job wasn't as nice because I was rushing to get the whacking over with
- Buy short pieces of pipe because it is hard to use them again after making a cup off one end (requires cleaning the end up with a hacksaw cut to start egain)
- 1-1/4" pipe is too big for most candles, so I have switched to 1" to give that a try
Saturday, January 9, 2010
Leaves!
Thursday, December 17, 2009
A Leaf
Jeff made a beautiful leaf while blacksmithing the other day. It was quite an accomplishment because leaves have been a challenge for him; give him something functional any day over an organic, decorative piece. But, he wanted to learn how to tap into that side of his craft, and he certainly succeeded!
Tuesday, January 5, 2010
Wednesday, December 30, 2009
Wednesday, December 9, 2009
Hot from the past -- Peter Ross Bio (published in December 2009)
Was sent a neat article today from a friend: http://www.newsobserver.com/life/home_garden/story/224230.html
Hot from the past
BY DIANE DANIEL - CORRESPONDENT
Send suggestions to diane@bydianedaniel.com
By his standards, the 1905 farmhouse Peter Ross shares with his wife, Louise Barnum, is not all that old. Ross, a nationally known blacksmith, has to explain to potential customers that when he says "historical restoration" work, he refers to buildings dating from 1650 to 1840.
After 25 years of heading up the blacksmith shop at Colonial Williamsburg in Virginia, Ross moved to Chatham County in 2006, after marrying Barnum, a longtime area real estate agent. (Ross moved from Forge Road in Virginia to White Smith Road here.)
Before renovating their home on 25 acres outside of Siler City, Ross first set up the studio where he makes custom hardware, tools and utensils for restoration projects. Current projects include supplying kitchen utensils and hardware for a privately owned 1750s kitchen in Virginia, making circa-1820s door hinges and locks for a museum in eastern Tennessee, and creating a lock to match an existing door at Thomas Jefferson's Monticello, which dates to the late 1700s.
"Up until now I've worked only in the historic house restoration field, but this year I'm trying something new - a line of historically inspired but contemporary iron pieces that people can use in their homes," said Ross, 55. "Those could be kitchen utensils, tools for wood stoves and fireplaces, and brackets for lights."
Ross decided to add another line of work, although he typically has a backlog of restoration jobs, because he wanted to reach out locally; most of his clients are in other states. "I wanted a way of being connected to the community, to develop relationships with other artists and the public," Ross said. To that end, he signed up to be a stop on the Chatham Studio Tour, where artists open their workspaces to the public. The tour is this weekend and next. Ross will give demonstrations with his forge, anvil, hammer and tongs, something he's used to after speaking with the hundreds of thousands of Williamsburg tourists over the years.

First a hobby
Ross' association with museums began when he was 17, living on Long Island, N.Y. He and his father took a blacksmith class at a carriage museum in Stony Brook. "They had a blacksmith shop, and would teach classes in the community," Ross said. "They taught us to make simple hooks, and I just loved it. Of course neither one of us thought it would lead to a blacksmithing career."
Ross then became perhaps the only teenager on the East Coast to set up a blacksmith shop in the corner of his garage. "I played around with it as a hobby for a while, and then I volunteered at another museum on Long Island, a reconstructed town called The Old Bethpage Village Restoration. That was enough to convince me to find a college that had some kind of craft program."
Ross ended up at the Rhode Island School of Design, where he met his mentor, Dick Everett of Connecticut, who specializes in restoring 17th- and 18th-century hardware and furnishings. "He was in an old town, surrounded by old houses," Ross said. "I worked for him with the idea that I'd eventually open my own business."
And he did, in 1976 on Deer Isle, Maine, also home to Haystack Mountain School of Crafts. "It's just a beautiful, breathtaking spot, right on the ocean," he said. But the Williamsburg job beckoned three years later.
Past methods
"It's a fascinating environment," he said of the country's most famous living history museum. "It's a great academic institution. You're surrounded with other professionals studying restoration - curators, architects, archaeologists. But you're also dealing with tourists who often have no or little knowledge, and so your job is to educate them. It's an interesting combination."
At one point, Ross as master blacksmith had a staff of seven blacksmiths. "We had the same staff of blacksmiths for 12 years," he said. "It was a very skilled group." About half his time was spent with the public and the other half working on restoration projects at the museum. "I was hired to turn the blacksmithing into a more academic program instead of a souvenir-oriented program, so it was an exciting time to be there," Ross said. "There was a tremendous shift in many of the crafts there to do more research, to study long-developed techniques and to understand decorative arts from the maker's viewpoint. We got to look at everything with a fresh eye."
One of the things Ross learned and often lectured about was the difference between contemporary and pre-industrial aesthetics. "Our job was to re-create old pieces, and the methods in which they'd been made. It was a revelation to me that when you don't have modern tools at your disposal, not only are the tools you're using different, but the whole thought process is markedly different. You don't use the same sequence of steps. It's like cooking without a recipe, when you go by taste and sense and feel."
Nature's model
The 18th-century worker, he said, was led by nature's infinite variety. "The aesthetic ideal was nature. Like if you have two maple leaves. They have the same character, but are different in size and shape. That was the function of handwork through the ages until industrialization. Now it's all about uniformity and measured precision, sometimes even in ways that can be detrimental to the work."
Ross' more contemporary forged metal work won't be a huge stretch from his restoration work because he's basing the designs on historical pieces. "I'm not sure how much of the new stuff I'll do, but it's something I wanted to try. We'll see how it goes." No, he answered, he doesn't have a Web site showing his contemporary work. He is, after all, a little stuck in the 18th century.
Hot from the past
BY DIANE DANIEL - CORRESPONDENT
Send suggestions to diane@bydianedaniel.com
By his standards, the 1905 farmhouse Peter Ross shares with his wife, Louise Barnum, is not all that old. Ross, a nationally known blacksmith, has to explain to potential customers that when he says "historical restoration" work, he refers to buildings dating from 1650 to 1840.
After 25 years of heading up the blacksmith shop at Colonial Williamsburg in Virginia, Ross moved to Chatham County in 2006, after marrying Barnum, a longtime area real estate agent. (Ross moved from Forge Road in Virginia to White Smith Road here.)
Before renovating their home on 25 acres outside of Siler City, Ross first set up the studio where he makes custom hardware, tools and utensils for restoration projects. Current projects include supplying kitchen utensils and hardware for a privately owned 1750s kitchen in Virginia, making circa-1820s door hinges and locks for a museum in eastern Tennessee, and creating a lock to match an existing door at Thomas Jefferson's Monticello, which dates to the late 1700s.
"Up until now I've worked only in the historic house restoration field, but this year I'm trying something new - a line of historically inspired but contemporary iron pieces that people can use in their homes," said Ross, 55. "Those could be kitchen utensils, tools for wood stoves and fireplaces, and brackets for lights."
Ross decided to add another line of work, although he typically has a backlog of restoration jobs, because he wanted to reach out locally; most of his clients are in other states. "I wanted a way of being connected to the community, to develop relationships with other artists and the public," Ross said. To that end, he signed up to be a stop on the Chatham Studio Tour, where artists open their workspaces to the public. The tour is this weekend and next. Ross will give demonstrations with his forge, anvil, hammer and tongs, something he's used to after speaking with the hundreds of thousands of Williamsburg tourists over the years.

First a hobby
Ross' association with museums began when he was 17, living on Long Island, N.Y. He and his father took a blacksmith class at a carriage museum in Stony Brook. "They had a blacksmith shop, and would teach classes in the community," Ross said. "They taught us to make simple hooks, and I just loved it. Of course neither one of us thought it would lead to a blacksmithing career."
Ross then became perhaps the only teenager on the East Coast to set up a blacksmith shop in the corner of his garage. "I played around with it as a hobby for a while, and then I volunteered at another museum on Long Island, a reconstructed town called The Old Bethpage Village Restoration. That was enough to convince me to find a college that had some kind of craft program."
Ross ended up at the Rhode Island School of Design, where he met his mentor, Dick Everett of Connecticut, who specializes in restoring 17th- and 18th-century hardware and furnishings. "He was in an old town, surrounded by old houses," Ross said. "I worked for him with the idea that I'd eventually open my own business."
And he did, in 1976 on Deer Isle, Maine, also home to Haystack Mountain School of Crafts. "It's just a beautiful, breathtaking spot, right on the ocean," he said. But the Williamsburg job beckoned three years later.
Past methods
"It's a fascinating environment," he said of the country's most famous living history museum. "It's a great academic institution. You're surrounded with other professionals studying restoration - curators, architects, archaeologists. But you're also dealing with tourists who often have no or little knowledge, and so your job is to educate them. It's an interesting combination."
At one point, Ross as master blacksmith had a staff of seven blacksmiths. "We had the same staff of blacksmiths for 12 years," he said. "It was a very skilled group." About half his time was spent with the public and the other half working on restoration projects at the museum. "I was hired to turn the blacksmithing into a more academic program instead of a souvenir-oriented program, so it was an exciting time to be there," Ross said. "There was a tremendous shift in many of the crafts there to do more research, to study long-developed techniques and to understand decorative arts from the maker's viewpoint. We got to look at everything with a fresh eye."
One of the things Ross learned and often lectured about was the difference between contemporary and pre-industrial aesthetics. "Our job was to re-create old pieces, and the methods in which they'd been made. It was a revelation to me that when you don't have modern tools at your disposal, not only are the tools you're using different, but the whole thought process is markedly different. You don't use the same sequence of steps. It's like cooking without a recipe, when you go by taste and sense and feel."
Nature's model
The 18th-century worker, he said, was led by nature's infinite variety. "The aesthetic ideal was nature. Like if you have two maple leaves. They have the same character, but are different in size and shape. That was the function of handwork through the ages until industrialization. Now it's all about uniformity and measured precision, sometimes even in ways that can be detrimental to the work."
Ross' more contemporary forged metal work won't be a huge stretch from his restoration work because he's basing the designs on historical pieces. "I'm not sure how much of the new stuff I'll do, but it's something I wanted to try. We'll see how it goes." No, he answered, he doesn't have a Web site showing his contemporary work. He is, after all, a little stuck in the 18th century.
Subscribe to:
Posts (Atom)




.jpg)