Sovereignty Module: Strike While Hot
Complete Blacksmithing Projects: From First Heat to Finished Tools
The blacksmith is civilization's backbone — every other trade depends on metal tools. This campaign covers forge setup, essential techniques, and step-by-step projects for the tools that build everything else.
Chapter 1: Forge Setup
| Component | Materials | Size | Function | Cost | Priority |
|---|---|---|---|---|---|
| Forge (fire pot) | Steel/cast iron or brick | 12-18" fire pot | Contains and concentrates fire | Moderate | Critical |
| Bellows/blower | Leather + wood OR hand crank | Match forge size | Forces air into fire | Moderate | Critical |
| Anvil | Cast steel (or large rock/railroad track) | 100-300 lbs ideal | Work surface | High | Critical |
| Hammer (cross-peen) | Tool steel, 2-3 lbs | Standard | Primary forming tool | Low | Critical |
| Tongs (flat jaw) | Mild steel | 18-24 inches | Hold hot metal | Low (make first) | Critical |
| Vise (post/leg) | Cast iron/steel | 4-6 inch jaw | Hold work for filing/bending | Moderate | High |
| Slack tub | Metal or stone container | 5-10 gallons | Quenching | Very low | High |
| Coal/charcoal | Bituminous coal or hardwood charcoal | Ongoing supply | Fuel | Ongoing | Critical |
Forge alternatives: 1) Brake drum forge: car brake drum + pipe for air inlet + hand bellows. 2) Ground forge: hole in ground with clay lining + tuyere from side. 3) Brick forge: stack fire bricks into U-shape with air pipe at bottom. 4) Box forge: wooden box lined with clay, side-blast tuyere. Any reaches forging temperature with forced air and good fuel.
Chapter 2: First Projects
| Project | Stock | Techniques Used | Time | Difficulty | Teaches |
|---|---|---|---|---|---|
| S-hook | 1/4" round, 8" long | Tapering, scrolling, bending | 15-30 min | Very low | Heat control, basic shaping |
| J-hook | 3/8" round, 6" long | Tapering, bending, punching | 15-30 min | Low | Punching holes |
| Tent stake | 3/8" round, 12" long | Tapering, heading | 10-20 min | Very low | Drawing out, upsetting |
| Bottle opener | 1/4" x 1" flat, 6" long | Punching, drifting, bending | 30-45 min | Low | Hole making |
| Tongs (first pair) | 3/8" round, 18" each | Drawing, bending, riveting | 2-3 hours | Moderate | Complex multi-step |
Chapter 3: Essential Tool Projects
| Tool | Stock Size | Steel Type | Heat Treatment | Time | Priority |
|---|---|---|---|---|---|
| Cold chisel | 3/4" round x 6" | Medium-high carbon | Harden tip, temper to purple | 1-2 hours | Critical |
| Center punch | 1/2" round x 5" | High carbon | Harden tip, temper to straw | 45-60 min | High |
| Nail header | 1" square x 4" | Medium carbon | Harden face | 1-2 hours | Critical |
| Drift (round) | 3/4" round x 8" | Medium carbon | Harden working end | 1-2 hours | High |
| Hardy (hot cut) | Fit hardy hole | High carbon | Harden edge, temper to purple | 2-3 hours | High |
| Fuller (top) | 1" round x 10" | Medium carbon | Harden face | 1-2 hours | Moderate |
| Flatting hammer | 2-3 lb head | Medium carbon | Harden faces | 3-5 hours | High |
Nail making: 1) Heat 1/4" square rod to yellow heat. 2) Taper to point (4 blows, rotate 90 between). 3) Cut almost through at desired length. 4) Insert in nail header hole. 5) Break off from rod. 6) Flatten top into head (2-3 blows). 7) Drop into water. 8) Rate: 1 nail per minute for experienced smith.
Chapter 4: Knife Making
| Step | Temperature | Tools | Time | Critical Factor |
|---|---|---|---|---|
| Stock selection | N/A | Files (spark test) | 10 min | Must be high-carbon steel |
| Profiling | Yellow-orange | Hammer, anvil | 1-2 hours | Even thickness |
| Beveling | Orange-yellow | Hammer, anvil | 1-2 hours | Even bevel both sides |
| Normalizing | Cherry red, air cool | Forge | 30 min (3 cycles) | Relieves stress |
| Hardening | Cherry red, quench | Forge, oil/water | 5 min | Even heat, quick quench |
| Tempering | Straw-bronze (400-450F) | Oven or torch | 1-2 hours | Even temperature |
| Grinding/filing | Cold | Files, stones, sandpaper | 2-4 hours | Don't overheat |
| Handle | Cold | Wood, pins, rivets | 1-2 hours | Comfortable, secure |
| Sharpening | Cold | Whetstones | 30-60 min | Consistent angle (15-20) |
Chapter 5: Forge Welding
| Method | Temperature | Flux | Strength | Difficulty | Application |
|---|---|---|---|---|---|
| Fagot weld | White heat | Borax | Very high | High | Building up stock |
| Scarf weld | White heat | Borax | Very high | High | Joining bars end-to-end |
| Lap weld | White heat | Borax | High | Moderate-high | Overlapping joints |
| Riveting | Cold or warm | None | Moderate | Low | Sheet metal, straps |
Forge welding procedure: 1) Clean and prepare surfaces. 2) Heat to bright orange, apply borax flux. 3) Return to fire, heat to white/sparking. 4) Remove quickly (2-3 seconds window). 5) Place together on anvil. 6) First blow seats the joint. 7) Work from center outward. 8) If it fails: reflux, reheat, retry.
Reference Card
- Make tongs first (you need tongs to make everything else). 2. Yellow heat for shaping (orange too cold, white too hot). 3. Let the hammer bounce (relaxed grip saves energy). 4. Quench in oil for knives (water is too aggressive, causes cracks). 5. Temper immediately after hardening (brittle steel breaks). 6. Spark test identifies steel (more forks = more carbon = better edges). 7. Borax is essential flux (prevents oxidation at weld joint). 8. Heat the work not the air (keep metal in fire's sweet spot).