# Sovereignty Module: Build the Forge

## Complete Forge Construction, Tool Making, and Blacksmithing Setup Guide

The forge is the foundation of all metalworking. This campaign covers building a forge from scratch, making essential tools, and establishing a complete blacksmithing workshop.

### Chapter 1: Forge Types

| Forge Type | Fuel | Temperature | Cost | Portability | Best For |
|---|---|---|---|---|---|
| Side-blast coal forge | Coal/coke | 2,500°F+ | Low-moderate | Moderate | Traditional blacksmithing, all work |
| Bottom-blast coal forge | Coal/coke | 2,500°F+ | Moderate | Low | Heavy work, large pieces |
| Charcoal forge (JABOD) | Charcoal | 2,300°F | Very low | High | Beginners, primitive, off-grid |
| Gas forge (propane) | Propane | 2,300°F | Moderate | High | Clean, consistent, easy to use |
| Brake drum forge | Coal/charcoal | 2,400°F | Very low | Moderate | Beginners (built from car parts) |

### Chapter 2: JABOD Forge Construction (Just A Box Of Dirt)

| Step | Action | Materials | Details |
|---|---|---|---|
| 1 | Build box (wood frame or stone/brick) | 2×4 lumber or stacked brick | 24×24×8 inches minimum interior |
| 2 | Fill with clay/dirt mixture | Clay-rich soil (or mix clay + sand) | Pack firmly, 4-6 inches deep |
| 3 | Form fire pot (depression in center) | Hands or bowl shape | 6-8 inches diameter, 3-4 inches deep |
| 4 | Install tuyere (air pipe) | 1-1.5 inch steel pipe | Enters from side, angled slightly down into fire pot |
| 5 | Connect air supply | Bellows, hand blower, or hair dryer | Must be controllable (too much air = burns steel) |
| 6 | First fire: cure the clay slowly | Small fire, build gradually | Prevents cracking from thermal shock |

Total cost: Nearly free (scrap materials). Build time: 1-2 hours. Fully functional for all basic blacksmithing.

### Chapter 3: Essential Tools (Priority Order)

| Tool | Function | Can Be Made? | Minimum Specification |
|---|---|---|---|
| Anvil (or substitute) | Work surface | Railroad track, large hammer head, or stone | Flat, hard surface. 50+ lbs preferred. |
| Hammer (cross pein, 2-3 lbs) | Primary forming tool | Yes (from rebar or spring steel) | 2-3 lbs, good handle, flat face |
| Tongs (flat jaw) | Hold hot metal | Yes (first project after hammer) | Must grip work securely |
| Vise (post or leg vise) | Hold work for filing, bending | Difficult (purchase recommended) | 4+ inch jaws, mounted solidly |
| Quench tank | Cool/harden steel | Any metal container + water | Large enough for longest piece |
| Wire brush | Clean scale from hot metal | Purchase | Stiff wire bristles |
| Files (bastard + smooth) | Shaping, finishing | No (purchase) | 10-12 inch flat + half-round |
| Punch (hot punch) | Make holes in hot metal | Yes (from coil spring or rebar) | Tapered point, mushroom-proof head |
| Chisel (hot cut) | Cut hot metal | Yes (from coil spring) | Sharp edge, handled or hardy-hole mount |
| Drift (mandrel) | Open/shape holes | Yes (from mild steel) | Tapered, smooth finish |

### Chapter 4: Steel Types for Blacksmithing

| Steel Source | Carbon Content | Hardenable? | Best For | Identification (Spark Test) |
|---|---|---|---|---|
| Mild steel (A36, rebar) | 0.05-0.25% | No (stays soft) | Hooks, brackets, decorative | Few sparks, orange, no bursts |
| Medium carbon (1045) | 0.40-0.50% | Yes (moderate) | Tools, hammers, tongs | More sparks, some bursting |
| High carbon (1075-1095) | 0.75-0.95% | Yes (hard + brittle) | Knives, chisels, springs | Many sparks, bright bursting |
| Coil spring (5160) | 0.56-0.64% + chromium | Yes (tough) | Knives, tools, tongs | Moderate sparks, some burst |
| Leaf spring (5160) | 0.56-0.64% + chromium | Yes (tough) | Large knives, tools | Same as coil spring |
| Railroad spike (1030-1040) | 0.30-0.40% | Marginal | Decorative, light tools | Moderate sparks, few bursts |
| File (W1, 1095) | 0.95-1.0% | Yes (very hard) | Knives, scrapers, punches | Many bright bursting sparks |

### Chapter 5: Basic Operations

| Operation | Temperature | Color | Technique | Common Errors |
|---|---|---|---|---|
| Drawing out (lengthening) | Bright orange-yellow | 1,800-2,100°F | Hammer on far edge of anvil, rotate 90° | Hitting too cold (cracks), uneven |
| Upsetting (thickening) | Bright orange | 1,800-2,000°F | Hit end-on (compress length into width) | Buckling (heat only the area to upset) |
| Bending | Orange-yellow | 1,600-1,900°F | Over anvil edge or in vise | Sharp bends (use radius), cold spots crack |
| Punching | Bright orange-yellow | 1,800-2,100°F | Drive punch 2/3 through, flip, punch from other side | Punching too cold, off-center |
| Splitting | Bright orange-yellow | 1,800-2,100°F | Hot chisel on anvil face | Cutting into anvil face (use hardy) |
| Forge welding | White/sparking | 2,300°F+ | Flux (borite), quick overlapping blows | Too cold (won't stick), too hot (burns steel) |
| Scrolling | Orange | 1,600-1,800°F | Start curl at tip over horn, work back | Uneven heat = uneven scroll |
| Twisting | Even orange throughout | 1,600-1,800°F | Grip in vise, twist with wrench | Uneven heat = uneven twist |

### Chapter 6: Heat Treatment

| Process | Purpose | Procedure | Result |
|---|---|---|---|
| Hardening | Make steel hard (and brittle) | Heat to critical temp (cherry red, non-magnetic) → quench in oil/water | Hard but brittle (will shatter) |
| Tempering | Reduce brittleness, add toughness | After hardening: heat to specific color (see below) | Tough + hard (usable tool) |
| Annealing | Make steel soft (for filing/drilling) | Heat to cherry red → cool VERY slowly (bury in ash/vermiculite) | Soft, machinable |
| Normalizing | Relieve stress, refine grain | Heat to cherry red → air cool | Even grain structure, moderate hardness |

Tempering colors (after hardening, polish bright, heat slowly):

| Color | Temperature | Hardness | Best For |
|---|---|---|---|
| Pale straw | 400°F | Very hard | Razors, engraving tools |
| Dark straw | 450°F | Hard | Knives, chisels, plane blades |
| Bronze/brown | 500°F | Moderate-hard | Axes, wood chisels, punches |
| Purple | 540°F | Moderate | Springs, screwdrivers |
| Blue | 590°F | Tough (less hard) | Springs, saws, swords |
| Grey-blue | 640°F | Very tough | Springs under heavy shock |

### Reference Card

1. JABOD forge: box of dirt + pipe + air source. Build in 1-2 hours. Free. Fully functional.
2. Anvil substitute: railroad track (mounted vertically), large sledgehammer head, or flat boulder.
3. First projects: S-hook → tongs → punch → chisel → knife. Each builds skills for the next.
4. Steel identification: spark test on grinder. More bursting sparks = higher carbon = hardenable.
5. Forging temperature: orange-yellow (1,800-2,100°F). Never hammer below dark red (cracks).
6. Hardening: heat to non-magnetic (cherry red) → quench. Then ALWAYS temper (straw-to-blue color).
7. Forge welding: white heat + flux (borax) + fast light blows. Hardest basic skill. Practice on mild steel.
8. Coil/leaf springs: best free source of tool steel. 5160 (tough, hardenable, forgiving).