Complete Chain Making and Blacksmithing Links: From Rod to Chain
Chain is essential for draft animals, lifting, anchoring, and securing. This campaign covers link forging, welding, chain assembly, and testing.
Chapter 1: Chain Types
Type
Link Shape
Use
Strength
Difficulty
Trace chain (draft)
Oval, elongated
Connecting draft animals to implements
High
Moderate
Log chain
Round or oval, heavy
Skidding logs, heavy hauling
Very high
Moderate-high
Tie chain
Round, light
Tethering animals
Moderate
Low-moderate
Decorative chain
Various
Hanging signs, lamps
Low
Low
Proof chain (tested)
Oval, uniform
Critical lifting, anchoring
Very high (tested)
High
Chapter 2: Link Forging
Basic link forging: 1) Start with round rod (3/8-1/2 inch for medium chain). 2) Cut rod to length (circumference of desired link plus overlap for weld). 3) Heat rod to bright orange. 4) Bend around horn of anvil into oval or round shape. 5) Overlap ends (scarfed joint for forge welding). 6) Heat overlapped ends to welding temperature (bright yellow/white). 7) Apply flux (borax) to joint. 8) Forge weld: hammer overlapped ends together on anvil. 9) Shape link on horn to final oval form. 10) Cool and inspect weld (no gaps, no cold shuts).
Link Size
Rod Diameter
Link Length
Link Width
Chain Strength (approx)
Light (tie chain)
1/4 inch
1.5 inches
3/4 inch
500-1,000 lbs
Medium (trace chain)
3/8 inch
2 inches
1 inch
1,500-3,000 lbs
Heavy (log chain)
1/2 inch
2.5 inches
1.25 inches
3,000-6,000 lbs
Very heavy (anchor)
5/8 inch
3 inches
1.5 inches
5,000-10,000 lbs
Chapter 3: Chain Assembly
Assembly process: 1) Forge first link and close (weld shut). 2) Thread next rod through first link before bending. 3) Bend second rod around horn (with first link threaded on). 4) Weld second link shut. 5) Thread third rod through second link. 6) Continue alternating: thread, bend, weld. 7) Each link passes through the previous one. 8) Maintain consistent link size (use jig or template). 9) Test each weld by striking link against anvil edge. 10) A chain is only as strong as its weakest link.
Chapter 4: Chain Hardware
Hardware
Purpose
Forging Method
Difficulty
Grab hook
Shortening chain, attaching to load
Forge from 3/4 inch bar, bend hook, forge throat
Moderate
Slip hook
Quick release under load
Similar to grab hook with wider throat
Moderate
Clevis
Connecting chain to implement
Forge U-shape from flat bar, drill pin hole
Low-moderate
Swivel
Prevents chain from twisting
Forge eye and hook that rotate freely
High
Ring (master link)
End termination, attachment point
Forge weld large ring
Low-moderate
S-hook
Quick connection
Bend rod into S shape
Very low
Chapter 5: Testing and Maintenance
Test
Method
Purpose
When
Visual inspection
Examine each link for cracks, wear, deformation
Identify obvious defects
Before every use
Proof test
Load to 2x working load, hold, release
Verify strength
After manufacture
Drop test
Drop chain on hard surface, listen for ring
Detect cracked links (dull sound = crack)
Periodically
Stretch test
Measure length before and after loading
Detect elongation (sign of overload)
After heavy use
Reference Card
A chain is only as strong as its weakest link (every link must be forged and welded to the same standard; one poor weld and the entire chain fails under load). 2. The forge weld is the critical skill (chain links are closed by forge welding; a cold shut or incomplete weld will fail; practice welding before making chain). 3. Thread before bending (each new link must be threaded through the previous link before bending and welding; forgetting this step means cutting a link to add the new one). 4. Use a jig for consistency (a simple bending jig ensures every link is the same size; inconsistent links make weak, ugly chain). 5. Flux prevents oxidation (borax flux applied to the scarfed joint before welding prevents oxide scale from forming; oxide in the weld creates a weak joint). 6. Test every link (strike each welded link against the anvil edge; a good weld rings; a bad weld cracks or opens; catch failures before the chain goes into service). 7. Never exceed working load (chain rated for 3,000 pounds should never be loaded beyond 3,000 pounds; the proof test at 2x working load is a one-time verification, not an operating limit). 8. Chain making is meditative work (the rhythm of cut, heat, bend, thread, weld, shape, repeat produces a useful product and develops the smith's most important skill: the forge weld).
