Blacksmithing User Guide

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Shop Area: Metal Shop

Tool: Blacksmithing

Requires in-person training: Yes 

Procedure Number

UG 130-01, Rev. 0

Date

DRAFT

 

GENERAL

Blacksmithing Tools:

  • Hell's Forge a propane forge
  • Anvils
  • Leg vise
  • Hand tools
  • 2x72" Belt Grinders / Polishing

SAFETY

  • Always wear approved face shield.
  • Before operating equipment, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.
  • Non-slip footwear or anti-skid floor strips are recommended.
  • Closed toe shoes are required when working in a shop area.
  • NEVER LEAVE THIS UNIT BURNING UNATTENDED UNDER ANY CIRCUMSTANCE. THIS UNIT IS TO BE USED FOR HEATING METAL ONLY AND SHOULD NEVER BE USED FOR ANY OTHER PURPOSE.

REFERENCE

PROCEDURE

Hell's Forge:

  1. Burner tip comes with a small rubber cap or caps that is to be used for leak checks only and must be removed prior to use.
  2. While rubber caps are sealing the burner or multiple burners, slowly turn on the propane (DO NOT SMOKE OR HAVE ANY FLAMES PRESENT WHILE PERFORMING THIS PROCEDURE).
  3. While gas is on and caps are sealed, spray soapy water (Water and Dishwashing detergent) at every connection including your propane tank connection while observing for any bubbles present which indicates a gas leak. (Do not use if gas leak is occurring).
  4. If a rare gas leak occurs, unscrew fitting and apply gas approved pipe sealant on the threads and re-screw back on to fitting.
  5. After the leak check has been performed, turn off all propane sources.
  6. Slide the red burner tubes on each side of the stainless steel burner assembly (Just the 1 burner on single models) so that the washers rest on the top of the tubes and tighten the set screws with the Allen wrench to secure. Slide the red burner tubes into the burner holders evenly into the forge to be flush with the blanket. You don't want to see the red tube inside the forge. Do not insert them farther as the back pressure will cause the flame to flutter. Tighten the 3/8” bolts on the holders to secure the burner tubes. (Do not overtighten)
  7. Connect the hose regulator to the brass flare fitting. Use a separate wrench on both the brass flare fitting and the regulator connection to tighten. (Do not use any thread sealer on this fitting or overtighten)
  8. Make sure regulator is in the off position, then connect regulator to propane tank (BE SURE PROPANE AND REGULATOR ARE OFF)
  9. Once refractory has been installed and dried, gently lay fire brick in the bottom of the forge housing while taking care not to drag across or damage the fire blanket.
  10. It is easier to slide the red burner tubes onto the burner assembly before the burner tubes are installed in the forge body.
  11. Always use 2 wrenches at all connections to support 1 nut while tightening the other to prevent damage to threads and fittings. (NEVER USE ONLY 1 WRENCH AS DAMAGE WILL OCCUR)
  12. NEVER PLACE PROPANE REGULATOR HOSE AT THE OPENING OF THE FORGE. IT MUST BE TO THE SIDE OF THE FORGE OPENING, AWAY FROM THE MAIN HEAT SOURCE
  13. WHEN OPERATING ON 1 BURNER, CLOSE THE CHOKE ON THE BURNER TUBE THAT IS NOT IN USE. WHEN FORGING IS COMPLETE, (USING 1, 2, or 3 BURNERS), MAKE SURE TO CLOSE ALL CHOKES AFTER USE WHILE THE HEAT DISSIPATES.

Hell's Forge Lighting Instructions

  1. Always light the flame inside of the forge (Never light at the burner tube holes!)
  2. Use of a piece of flammable material (Paper, long fireplace match, etc) inside of the forge which must be lit prior to turning on any gas (Turn gas shut off valve OFF on one burner as you should light one burner at a time. Once one burner is lit, you may open the valve. The other burner should light off of the other, but if not use the same procedure to light the other burner.)
  3. Place the lit flame directly under the burner tube opening
  4. Keep hands face and other flammable materials away from the forge opening while lighting!!!!
  5. Slowly open your gas regulator and listen for a flutter of the flame lighting. As it lights, slowly increase the gas pressure on the regulator until your flame stabilizes
  6. As a rule of thumb, the burner choke should be fully open exposing all holes in the burner tube for adequate air intake. You may have to slightly adjust the burner choke to stabilize a constant flame
  7. If your flame is not lit immediately upon turning on gas, turn your propane regulator immediately off!! Wait several minutes for the propane to dissipate before trying to light your flame again (NOT FOLLOWING THIS PROCEDURE IS DANGEROUS AND COULD RESULT IN INJURY OR DEATH)
  8. The flame should be jet blue and roaring through the burner tube to the inside of the forge. Never yellow. If yellow, see the FAQ page.
  9. Always start with a full propane tank as a tank that is almost empty will have low pressure and cause your flame to not ignite properly or stabilize
  10. AFTER FINISHING USE, MAKE SURE TO TURN OFF PROPANE SOURCE, DISCONNECT REGULATOR HOSE, AND STORE IN A PROPER SAFE PLACE.
  11. ALWAYS PERFORM A LEAK CHECK ANYTIME THE HOSE AND FITTINGS HAVE BEEN DISCONNECTED.

Hell's Forge HELLCOTE 3000 - Installation Instructions: (Must wear dust mask while handling HELLCOTE in a dry state)

Mixing:

  1.  Place entire contents of bag in a mixing container
  2. Gradually add small amounts of tap water, being very careful not to over saturate.
  3. Mix in a whipping fashion until the consistency is that of a milkshake (pourable). NOT TOO THICK!
  4. Using a paint brush or rubber gloved hands, place material inside the forge and spread evenly to approximately a 1/16”-1/8” coating while making sure to cover the entire blanket (including the ends)
  5. Make sure that the 2 pipes in the forge are clear of any refractory material prior to drying.
  6. Let air dry for 24 hours.  May still be soft, that’s ok. Next, light forge for 3 minutes, then turn off for 1 hour.
  7. Forge is now sealed, protected, and ready to use!
  8. Some hairline cracking may occur in the coating, which is common to all refractory material coatings

TROUBLESHOOTING

Hell's Forge

Problem:             My flame is yellow and low pressure, not jet blue?

Solution:             LP Tank low on propane

Not enough air entering the top burner tube holes, open up the chokes.

Too much wind blowing causing the flame to flutter and go out

Partially clogged burner tip, insert a piece of .035 wire or a torch tip cleaner in burner holes to   clear debris

Problem:             My regulator is freezing and causing low pressure and little flow

Solution:             LP Tank overfilled or moisture in the tank.

Purge tank to remove excess moisture or gas.  Always do outside in several second intervals to allow gas to dissipate during purging. Do not light forge or smoke during this process.

If this doesn't cure it, the regulator has switched to low pressure safety mode and must be disconnected from the tank and reconnected to reset.

Problem:             The regulator is leaking between it and the tank.  

Solution:             Do not operate it with a leak. You may have a scratch or gouge in your brass tank fitting causing the leak. Try the following to resolve the issue: First, attach to another propane tank to see if that makes a difference. Also try an “O” ring on the nipple and see if that works. 

Problem:             I found a small leak where the brass fitting connects to the steel tubes.

Solution:             More pipe sealant needs to be added to the connection.  Unscrew the copper tip with pliers, then apply more pipe thread sealer to the threads on the copper tip – being careful not to get the pipe sealer in the small hole in the copper tip.  Tighten the copper tip carefully – not too much pressure. We recommend Rectoseal 5 Pipe Sealer.

Problem:             Sputtering noise / slowing down of flame

Solution:             Regulator may not be turned up high enough creating enough pressure to disperse to both burners.

Problem:             I want to use a 100 lb. tank versus a 20 lb. tank. Can I use the same regulator?

Solution:             Yes, you can use any size tank you want as long as the fittings are the same and yes the same regulator can be used.

Problem:             I hear hissing sounds but have a blue flame and no leaks. Is everything fine?

Solution:             Yes, this is normal as long as there are no leaks.

Problem:             How do I know when the temperature is right to begin forging?

Solution:             The metal should be getting a bright yellow almost white color. Keep in mind the thicker metal will take more time to come up to forging temperature. Close off the end with firebrick to help increase the temperature.

Problem:             I’m only using one burner and noticed the rear burner choke hole is black. Is that a concern?

Solution:             Make sure the burner tube holes are closed off on the one you are not using.

Problem:             I melted the hose on my regulator. How can I order a replacement?

Solution:             Ordering off Amazon will be your best option. We can’t compete with those prices so we don’t sell this part. You will need to order a 0-20 psi propane regulator with at least a 4 ft. hose and 3/8” female flare fitting.  No specific brand recommended. If you have the MAX forge, order one that is a 0-30 psi.

Problem:          I am only using one burner but I see smoke coming from the other burner. Is this normal?

Solution:          Make sure the air holes in that burner are closed off. Also, make sure the ON and OFF valve is fully in the OFF position.

THIS IS THE END OF THE PROCEDURE