Sovereignty Module: Strike While Hot
Strike While Hot
Blacksmithing Projects: Essential Tools from the Forge
Blacksmithing Projects: Essential Tools from the Forge
Every civilization needs a smith. This campaign provides step-by-step projects from beginner to advanced, building the tool kit that builds everything else.
Chapter 1: Beginner Projects
| Project | Material | Time | Skills Practiced | Tools Made |
|---|---|---|---|---|
| S-hook (various sizes) | 3/8" round mild steel | 15-30 min | Drawing, scrolling, bending | Pot hangers, chain links |
| Tent stake | 3/8" square mild steel | 20 min | Drawing to point, heading | Camp equipment |
| Fire poker | 1/2" round mild steel | 30-45 min | Drawing, bending, handle scroll | Hearth tool |
| Nail (hand-forged) | 1/4" square mild steel | 10-15 min | Drawing, heading, cutting | Fasteners |
| Bottle opener | 1/4" × 1" flat mild steel | 30-45 min | Punching, bending, finishing | Useful gift/trade item |
| Barbecue fork | 3/8" round mild steel | 45-60 min | Drawing, splitting, bending | Kitchen tool |
| Wall hook | 1/4" × 1" flat mild steel | 20-30 min | Scrolling, punching, bending | Storage hardware |
| Chisel (cold) | 3/4" round medium carbon steel | 45-60 min | Drawing, heat treatment | Metalworking tool |
Chapter 2: Intermediate Projects
| Project | Material | Time | Key Techniques | Result |
|---|---|---|---|---|
| Tongs (flat jaw) | 1/2" round mild steel × 2 | 3-4 hours | Drawing, bending, riveting, fitting | Essential forge tool |
| Knife (simple) | Old file or leaf spring | 3-5 hours | Forging, grinding, heat treatment, handle | Cutting tool |
| Hammer (cross pein) | 1.5" round medium carbon steel | 4-6 hours | Punching, drifting, heat treatment | Forge tool |
| Hinge (strap) | 1/4" × 1.5" flat mild steel | 1-2 hours | Scrolling, punching, bending around mandrel | Door/gate hardware |
| Chain (links) | 3/8" round mild steel | 2-3 hours (per foot) | Bending, forge welding each link | Utility chain |
| Axe hatchet | Medium carbon steel (old axe to reshape) | 4-6 hours | Punching, drifting, drawing, heat treatment | Chopping tool |
| Draw knife | Leaf spring steel | 3-5 hours | Drawing, bending handles, heat treatment | Woodworking tool |
| Fireplace crane | 1/2" round + 1" flat mild steel | 4-6 hours | Bending, riveting, scrollwork | Hearth equipment |
Chapter 3: Advanced Projects
| Project | Material | Time | Mastery Demonstrated | Application |
|---|---|---|---|---|
| Broad axe | High carbon steel + mild steel body | 8-12 hours | Forge welding, drifting, heat treatment | Timber framing |
| Sword (simple) | High carbon steel (5160 spring steel) | 20-40 hours | Full blade forging, differential heat treatment | Defense, ceremony |
| Plow point | High carbon steel | 6-10 hours | Heavy forging, welding, heat treatment | Agriculture |
| Anvil (small) | Railroad track or large steel block | 10-20 hours | Heavy forging, hardening face | Forge equipment |
| Lock and key | Mild + spring steel | 8-15 hours | Precision filing, spring work, assembly | Security |
| Wagon tire | Mild steel flat bar | 4-8 hours | Bending to circle, welding, shrink-fitting | Transportation |
| Surgical tools | High carbon steel | 5-10 hours per tool | Precision forging, fine heat treatment, polish | Medical |
| Armor (mail links) | Mild steel wire (14-16 gauge) | 100+ hours | Wire drawing, riveting, pattern assembly | Defense |
Chapter 4: Tool Steel and Heat Treatment
| Steel Type | Carbon Content | Source (salvage) | Hardening | Tempering | Best For |
|---|---|---|---|---|---|
| Mild steel (1018) | 0.15-0.20% | Rebar, angle iron, plate | Cannot harden | N/A | Tongs, hooks, brackets |
| Medium carbon (1045) | 0.40-0.50% | Axles, connecting rods | Oil quench | Blue (springs), purple (axes) | Hammers, axes, punches |
| High carbon (1075-1095) | 0.75-0.95% | Files, springs, saw blades | Oil or water quench | Straw (knives), gold (chisels) | Cutting edges, springs |
| Tool steel (W1) | 0.90-1.10% | Drill bits, taps, dies | Water quench | Straw to gold | Precision cutting tools |
| Spring steel (5160) | 0.55-0.65% + chromium | Leaf springs, coil springs | Oil quench | Blue | Swords, large blades, springs |
Spark test: Hold steel against grinding wheel, observe sparks. Mild steel = long orange streams, few forks. Medium carbon = shorter streams, more forks. High carbon = short, bushy, many forks and stars. Tool steel = very short, dense burst of stars. Learn this test — identifies unknown steel.
Chapter 5: Forge Welding
| Step | Temperature | Indicator | Action | Critical Factor |
|---|---|---|---|---|
| 1. Prepare surfaces | Cold | N/A | Clean, scarfing (taper ends) | No scale, oil, or dirt |
| 2. Apply flux | Red heat | Metal starting to scale | Sprinkle borax on joint area | Flux prevents oxidation |
| 3. Heat to welding | White/sparkling | Surface looks "wet," sparks fly | Bring both pieces to same heat | Even heat critical |
| 4. Remove and strike | White heat (seconds count) | Both pieces at welding temp | Place together, strike firmly and fast | Speed — heat loss = failure |
| 5. Work the weld | Yellow-orange | Joint sealed | Continue forging to shape | Don't overheat (burns steel) |
Common failures: Dirty surfaces (scale prevents bonding). Uneven heat (one piece cooler). Too slow (heat lost before striking). Insufficient flux. Striking too hard (squeezes pieces apart). Practice on mild steel before attempting with high carbon.
Chapter 6: Setting Up a Community Forge
| Item | Priority | Source | Cost (relative) | Notes |
|---|---|---|---|---|
| Anvil (100+ lbs) | Essential | Salvage railroad track, or purchase | High | Heavier = better. Bolt to stump. |
| Forge (coal/charcoal) | Essential | Build from brake drum or steel plate | Low-moderate | Side-blast or bottom-blast design |
| Blower | Essential | Hand-crank blower, bellows, or electric | Moderate | Must reach welding heat |
| Hammer (2-3 lb cross pein) | Essential | Purchase or forge from stock | Low | Good quality handle critical |
| Tongs (3-4 pairs) | Essential | Forge your own (first project) | Low (labor) | Flat jaw, wolf jaw, bolt jaw |
| Vise (leg/post vise) | Very important | Salvage or purchase | Moderate-high | Mounted at elbow height |
| Quench tank | Essential | Any metal container + oil/water | Very low | Large enough to submerge work |
| Grinding wheel/belt | Important | Purchase | Moderate | For shaping and finishing |
| Drill press | Important | Purchase or build | Moderate-high | For precision holes |
| Coal/charcoal supply | Essential | Mine coal, or make charcoal | Ongoing | 50+ lbs on hand always |
| Steel stock (various) | Essential | Salvage + purchase | Ongoing | Organize by size and type |
| Safety equipment | Essential | Purchase | Low | Glasses, apron, ear protection |
Reference Card
- Start with mild steel: cannot be hardened, very forgiving. Learn hammer control, heat management, and basic operations.
- Spark test: identifies unknown steel. More sparks/forks = more carbon = hardenable. Learn this before heat treating.
- Heat colors: cherry red (forging), orange (drawing), yellow (upsetting), white (welding). Never forge below cherry red.
- Tongs: your first real project. Must fit the work snugly. Loose tongs = dangerous. Make multiple sizes.
- Heat treatment: harden (quench from non-magnetic), then ALWAYS temper (reheat to color). Straw for edges, blue for springs.
- Forge welding: clean surfaces, flux with borax, even white heat, fast firm blows. Practice on mild steel first.
- Anvil: face must be flat and smooth. Secure firmly. Work over the sweet spot (center of face over solid mass).
- Safety: always wear eye protection. Leather apron. Never quench near your body. Hot steel looks the same as cold steel.
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