Sovereignty Module: Shape the Iron
Forge and Form
Complete Blacksmithing Projects: Tools, Hardware, and Weapons
Complete Blacksmithing Projects: From Raw Stock to Finished Tools
Every tool the community needs can be forged. This campaign provides complete project instructions for essential blacksmithing products, from simple hooks to complex mechanisms.
Chapter 1: Essential Hardware
| Project | Difficulty | Time | Stock | Heat Cycles | Tools Required |
|---|---|---|---|---|---|
| Nail (various sizes) | Beginner | 5-10 min each | 1/4" square rod | 2-3 | Hammer, anvil, header |
| Hook (S-hook, J-hook) | Beginner | 10-15 min | 3/8" round rod | 3-4 | Hammer, anvil, horn |
| Chain link | Beginner | 10-15 min each | 3/8" round rod | 3-4 | Hammer, anvil, mandrel |
| Hinge (strap) | Intermediate | 30-45 min | 1/4" x 1" flat bar | 5-8 | Hammer, anvil, punch, drift |
| Door latch | Intermediate | 45-60 min | 1/4" x 1" flat bar | 6-10 | Hammer, anvil, punch, file |
| Lock (simple) | Advanced | 2-4 hours | Various flat/round stock | 15-20 | Full tool set, files |
| Bolt and nut | Intermediate | 20-30 min | 1/2" square rod | 4-6 | Hammer, dies, tap |
| Staple (fence) | Beginner | 3-5 min each | 1/4" round rod | 2 | Hammer, anvil |
| Ring (various) | Beginner | 10-15 min | Round rod (size varies) | 2-3 | Hammer, mandrel |
| Bracket (shelf) | Intermediate | 20-30 min | 1/4" x 1" flat bar | 4-6 | Hammer, anvil, vise |
Chapter 2: Cutting Tools
| Tool | Difficulty | Time | Steel Type | Heat Treatment | Edge Angle |
|---|---|---|---|---|---|
| Knife (general purpose) | Intermediate | 2-4 hours | High carbon (1080/1084) | Harden + temper (straw) | 20-25° |
| Axe head | Advanced | 4-8 hours | Medium carbon + steel bit | Harden bit only, temper | 25-30° |
| Chisel (wood) | Intermediate | 1-2 hours | High carbon (W1/1095) | Harden + temper (straw-bronze) | 25-30° |
| Chisel (cold, metal) | Intermediate | 1-2 hours | High carbon (S7/W1) | Harden + temper (blue) | 60-70° |
| Drawknife | Advanced | 3-5 hours | High carbon (1084) | Harden + temper (straw) | 25-30° |
| Plane iron | Advanced | 2-4 hours | High carbon (O1/W1) | Harden + temper (straw) | 25° |
| Scythe blade | Expert | 6-10 hours | High carbon, thin | Harden + temper (straw) | 15-20° |
| Scissors/shears | Advanced | 4-6 hours | High carbon (1084) | Harden + temper (straw) | 20-25° |
| Saw blade | Expert | 8-12 hours | Spring steel (1095) | Harden + temper (blue) | Filed teeth |
| Drill bit | Advanced | 1-2 hours | High carbon (W1) | Harden tip + temper (straw) | 118° point |
Knife forging procedure: 1) Select steel (1084 is forgiving, good edge). 2) Heat to bright orange (1500°F). 3) Draw out blade shape (taper from spine to edge). 4) Form tang (reduce to handle size). 5) Normalize 3x (heat to non-magnetic, air cool). 6) Grind/file to near-final shape (leave edge 1/16" thick). 7) Heat treat: heat to non-magnetic (cherry red), quench in warm oil (canola works). 8) Temper: clean blade, heat in oven 400°F for 1 hour (twice). 9) Final grind and sharpen. 10) Handle: drill tang hole in wood/antler, epoxy in place, shape handle.
Chapter 3: Agricultural Tools
| Tool | Difficulty | Time | Materials | Function | Lifespan |
|---|---|---|---|---|---|
| Hoe (garden) | Intermediate | 1-2 hours | 1/4" plate + round rod | Weeding, cultivating | 20+ years |
| Shovel/spade | Intermediate | 2-3 hours | 3/16" plate + pipe | Digging | 15-20 years |
| Pitchfork | Advanced | 3-5 hours | 1/2" round rod (4 tines) | Hay, manure | 20+ years |
| Sickle | Intermediate | 2-3 hours | High carbon flat bar | Grain harvest | 15+ years |
| Plow point | Advanced | 3-5 hours | Heavy plate, hardened | Breaking soil | 5-10 years (resharpened) |
| Mattock/pick | Advanced | 3-5 hours | Heavy stock, eye punch | Breaking ground, roots | 20+ years |
| Rake (iron) | Intermediate | 2-3 hours | 3/8" round rod | Gathering, leveling | 20+ years |
| Scythe | Expert | 6-10 hours | High carbon, thin forge | Mowing hay/grain | 20+ years |
| Pruning hook | Intermediate | 1-2 hours | High carbon flat bar | Tree trimming | 15+ years |
| Dibble (planting) | Beginner | 30-45 min | 1/2" round rod | Seed planting | Indefinite |
Chapter 4: Construction Tools
| Tool | Difficulty | Time | Materials | Function |
|---|---|---|---|---|
| Hammer head | Advanced | 2-4 hours | Medium carbon, heavy stock | Driving nails, general striking |
| Tongs (various) | Intermediate | 1-2 hours | Mild steel, 1/2" round | Holding hot metal |
| Punch (various) | Intermediate | 30-60 min | High carbon round rod | Making holes |
| Drift (various) | Intermediate | 30-60 min | High carbon, tapered | Enlarging/shaping holes |
| Wedge (splitting) | Beginner | 30-45 min | Medium carbon, heavy stock | Splitting wood |
| Adze | Advanced | 3-5 hours | High carbon + mild body | Shaping timber |
| Draw pin/spike | Beginner | 10-15 min | 3/8-1/2" square rod | Timber frame joinery |
| Masonry tools (trowel, point) | Intermediate | 1-2 hours | Mild steel plate | Bricklaying, pointing |
| Crowbar/pry bar | Intermediate | 1-2 hours | Medium carbon round rod | Leverage, demolition |
| Clamp (bar clamp) | Advanced | 2-3 hours | Flat bar + threaded rod | Holding work |
Chapter 5: Household Items
| Item | Difficulty | Time | Materials | Function |
|---|---|---|---|---|
| Cooking pot hook (trammel) | Intermediate | 1-2 hours | 1/4" x 1" flat bar | Adjustable pot height over fire |
| Fireplace tools (poker, shovel, tongs) | Intermediate | 2-4 hours (set) | 3/8" round + flat bar | Fire management |
| Candle holder | Beginner-Intermediate | 30-60 min | 1/4" round + flat bar | Lighting |
| Trivet (pot stand) | Intermediate | 1-2 hours | 3/8" round rod | Hot pot support |
| Cooking grate | Intermediate | 2-3 hours | 3/8" round rod | Cooking over fire |
| Ladle | Intermediate | 1-2 hours | Sheet metal + round rod | Serving liquids |
| Door handle | Intermediate | 30-60 min | 1/2" round rod | Door operation |
| Coat hooks | Beginner | 15-20 min each | 3/8" round rod | Storage |
| Boot scraper | Intermediate | 1-2 hours | 1/2" flat bar | Cleaning footwear |
| Towel bar | Beginner | 20-30 min | 1/2" round rod + brackets | Hanging |
Chapter 6: Weapons and Armor
| Item | Difficulty | Time | Materials | Notes |
|---|---|---|---|---|
| Spear point | Intermediate | 1-2 hours | High carbon flat bar | Leaf or triangular shape, hardened |
| Arrow points (broadhead) | Intermediate | 15-30 min each | High carbon sheet/rod | Various styles, hardened |
| Sword (short/long) | Expert | 20-40 hours | High carbon bar (1075/1084) | Most complex project |
| Shield boss | Intermediate | 2-3 hours | 14-16 gauge sheet | Dished over form |
| Mail rings | Intermediate | Ongoing (thousands) | Wire (14-16 gauge) | Coil, cut, rivet |
| Helmet (simple) | Advanced | 8-16 hours | 14-16 gauge sheet | Raised or segmented |
| Mace head | Intermediate | 2-3 hours | Heavy round stock | Flanged or ball |
| Crossbow bolt points | Intermediate | 15-20 min each | High carbon rod | Socket or tang |
| Armor plate (brigandine) | Advanced | Many hours (per plate) | 18-20 gauge sheet | Shaped, hardened, riveted to leather |
| Buckle (belt/armor) | Intermediate | 30-45 min | Mild steel rod + sheet | Forged frame + tongue |
Reference Card
- Steel selection matters: mild steel for non-cutting items (hooks, hinges, brackets). Medium carbon for impact tools (hammers, punches). High carbon (1080-1095) for cutting edges (knives, axes, chisels). Wrong steel = failed tool.
- Heat treatment is everything: a knife without proper hardening is just shaped metal. Normalize (3x), harden (quench from non-magnetic), temper (reheat to color). Skip any step = failure.
- Temper colors: straw (400°F) = cutting tools. Bronze (450°F) = springs, punches. Purple (500°F) = axes, cold chisels. Blue (550°F) = springs, saws. Match color to function.
- Start simple: nails, hooks, and tongs before knives and axes. Each project teaches techniques needed for the next. Rush to complex = frustration and waste.
- Maintain tools: a sharp tool is a safe tool. Sharpen regularly. Oil to prevent rust. Replace handles before they break. Well-maintained tools last generations.
- Forge welding: the master skill. Clean surfaces (wire brush), flux (borite), heat to white (welding heat), strike firmly. Practice on scrap before attempting on projects.
- Economy of heat: plan your work. While one piece heats, work another. Multiple heats = fuel consumed. Efficient smiths produce more with less charcoal.
- Safety: leather apron, safety glasses, ear protection. Hot metal looks cold. Never reach into the fire. Quench away from you. Respect the forge or it will teach you painfully.
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