# Sovereignty Module: Shape the Iron

## 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

1. 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.
2. 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.
3. 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.
4. Start simple: nails, hooks, and tongs before knives and axes. Each project teaches techniques needed for the next. Rush to complex = frustration and waste.
5. 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.
6. 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.
7. Economy of heat: plan your work. While one piece heats, work another. Multiple heats = fuel consumed. Efficient smiths produce more with less charcoal.
8. 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.