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Doug Ayen

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forge rebuild; kitchen [Apr. 9th, 2010|09:02 pm]
Doug Ayen
Well, I unpacked the new base brick. Wrong brick. I ordered the brick identified for my forge, but I guess they've changed the size over the years -- I measured the brick that arrived, and it matched the size in the order, but neither is the same size as my forge. Oh, well, on to plan C.

Forge reassembled; cracked and gaps patched with kaowool; forge set up on some rods over the slack tub, forge set on high, the open door facing down into the slack tub. After letting it preheat for a good hour, I used a stainless rake to scrape out the accumulated slag and crud into the tub. There was quite a bit.

While the forge was heating up and the slag dripping out, I got the ITC ready. ITC-100 is a colloidal suspension of finely divided zirconia, when applied as a surface coating in a furnace, it can increase efficiency by 30%, as it reflects ~98% of IR. Knock off the surface debris and loose stuff, apply via spray or brush, and let dry. It wears off pretty quickly as there's no binder (what binder would hold up to 3000F?) but it's pretty cheap and easy to apply.

Once the forge is cooled off, I'm going to mix up some bubble alumina refractory and coat the bottom of the forge with it, as well as fill in any craps and gaps and so on, let it dry, and I should be able to melt steel again in this puppy. Or, if not, I know I need to drag out my "thermonuclear recouperative fast-breeder forge" plans. :)

Why do I want this forge up and running asap? Because, as I was etching and polishing the cable damascus knife I've been working on, I discovered a cold shut (layers that didn't weld) right in the middle of the blade. Sigh. It might be recoverable; I'm going to try grinding away the bad bits tomorrow, but I'm afraid I'm going to have to start over. If worst comes to worse and I just can't make cable damascus work with my current skills and setup, I've got some nice damascus I got as a trade a while back I can turn into a knife quickly. I'd rather do it all myself, though.

Kitchen . . . actually, right now, I have no kitchen. The cabinets, counters, and appliances are all gone. Looks like I'm eating out this weekend. Tear-down is complete, Monday the new cabinets start going in; cabinets need to be in by Thursday, when the countertop people show up to measure for the new counters. The electrician rewiring the kitchen (there's only one circuit right now . . . and that's shared with the dining room. Except for the light, which ties in with the hall light.) is also running new wire out to the shop; it'll be nice to be able to move the welders, grinders, and other heavy power out of the garage -- not to mention not having the lights go out when I turn on the buffer in the shop.

Any questions?
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Comments:
[User Picture]From: fizzygeek
2010-04-10 02:54 pm (UTC)
I have no kitchen. The cabinets, counters, and appliances are all gone. Looks like I'm eating out this weekend

We could be talked into meeting you at that Italian place again...say, tonight sometime after 6:30pm. Just sayin'.
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