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βš’οΈ Blacksmithing and Hand Tools

How to set up a simple forge, pick the right scrap steel, forge and heat-treat it, and make or repair basic hand tools β€” chisels, punches, tongs, knives, axes β€” plus how to sharpen and re-handle the tools you already have. The full books are in Blacksmithing-Tools\ (Blacksmithing, Heat-Treating-Steel, Hand-Tools); axe and crosscut-saw manuals are in Engines-Motors\Chainsaws-and-Saws. Farm blacksmithing (plow shares) and a short Practical Action brief are in Homestead-Skills\Food-Crafts-Tools.

⚠️ Rules that prevent the worst injuries


πŸ”₯ A simple forge and anvil

Rule-of-thumb setups; the books have full plans.

Running the fire (TM 10-440, pp. 26–27; cross-sections of open and side-banked fires and a hollow fire; building the fire):

A forge fire drawn whole and in cross-section: a cone of coke burning over the tuyere in the center, with green coal packed around the edges Coke burns in the center right over the tuyere; green (unburned) coal packed round the edges cokes slowly and feeds it (TM 10-440, p. 27).

Fire problem Likely cause Fix
Steel comes out heavily scaled Fire too thin, too much air Build the fire deeper; less blast
Fire won't get hot Clinker choking the tuyere; wet or dusty fuel Rake out clinker; screen fuel
Fire spreads and wastes fuel Too much loose fuel, no banking Pack damp fuel around the edges

Anvil, Tuyere, Bellows, Swage block, Hardy tool.

πŸ“š Go deeper: ICS Blacksmith Shop Equipment β€” forges, blowers, bellows and anvil tools; Peace Corps Basic Techniques of Blacksmithing β€” building a forge and tools from scrap; TM 10-440 β€” fuel and fire management; Peace Corps Charcoal Making β€” making forge charcoal.

🌑️ Heat colors (in shade, not sunlight)

Color About Β°F What it's for
Dull red 1,050–1,175 Stop hammering β€” steel worked colder than this cracks.
Cherry red 1,250–1,375 Hardening temperature for most carbon steel; bending.
Orange to yellow 1,725–1,975 Normal forging heat β€” hammer here.
Bright yellow-white, "flowing" surface about 2,000 and up Forge welding (mild steel and wrought iron). A few sparks are normal at welding heat.
White, throwing a shower of sparks hotter still Burned. The steel is ruined β€” cut that part off.

(Β°F from TM 10-440's color table, p. 25; colors look different in different light and to different eyes, so learn them on your own forge.)

High-carbon steel burns at a lower heat than mild steel, so forge tool steel no hotter than orange-yellow. Burned steel can't be fixed by any later heat treatment. Keep hammering until the steel cools to a low red β€” forging refines the grain and makes it tougher. (TM 10-440, p. 24)

Basic moves: drawing out (hammering thinner and longer), upsetting (hammering the hot end to make it thicker), bending over the anvil horn or edge, punching holes hot, cutting on a hardy (a chisel set in the anvil), twisting, and forge welding. Ilgen's Forge Work and the Selvidge Shop Manual walk through each one step by step. Drawings: drawing out, upsetting, bending, hardy and chisels, top and bottom fullers; Blacksmith.

Punching a hole (TM 10-440, p. 33; drawing): center-punch the spot, heat to a good working heat, drive the punch two-thirds of the way through, flip the piece, and punch out from the other side over the anvil's round (pritchel) hole. Cool the punch often so it doesn't soften, and drop a little dry coal in a deep hole to stop the punch sticking.

A hand punch and three cross-sections of the hole: punched two-thirds through, turned over and punched through, and the finished hole Punch A: drive it about two-thirds through (B), turn the piece over and drive it through on the mark (C), then finish over the pritchel hole (D) (Selvidge, pp. 36–37).

Forge welding, step by step (Selvidge, pp. 45–47; TM 10-440, pp. 30–31):

  1. Prepare: upset each end to about 1Β½ times its thickness, then hammer a scarf (a bevel) on each, slightly rounded, not hollow, so scale squeezes out from the middle. (good and bad scarfs; shaping the scarf)
  2. Clean fire, clean anvil: rake out clinker, have plenty of coke ready, brush scale off the anvil face, and set your hammer where you can grab it.
  3. Heat slowly under a covering of live coals, turning the pieces so both heat evenly. (both pieces in the fire, scarf up)
  4. At bright red, sprinkle flux β€” borax or clean sand β€” on the scarfs; it keeps air off and melts the scale so it can squeeze out.
  5. Keep heating until the surface looks wet and flowing. Pull both pieces, knock off loose scale, lap the scarfs and strike light blows first, then heavier. (laying the pieces together; lap-weld drawings)
  6. Don't keep hammering once it drops below welding heat. If it doesn't stick, cut off the tips, re-scarf and try again. Use as few heats as possible.

Side view of two scarfed bar ends laid together: slightly rounded faces touching in the middle with scale squeezing out at the sides, and hollow faces touching only at the edges with scale trapped in a pocket Rounded scarfs meet in the middle and squeeze the scale out; hollow ones meet at the edges and trap it (a diagram drawn for this guide).

Forging problem Likely cause Fix
Cracks while hammering Worked below dull red Reheat sooner; stop at dull red
Sparks and a crumbly end Burned Cut back to sound metal
Weld won't stick Not hot enough, dirty fire, no flux, scale between faces Clean fire, flux at bright red, reach full welding heat
Weld lets go later Hammered after it cooled; hollow scarfs trapped scale Round the scarfs; weld in fewer, hotter heats
Thin tip burns before the thick part is hot Fast heating Heat slowly and keep the thin end back from the hot spot (Drew, p. 63)

Forge welding.

πŸ“š Go deeper: Selvidge Blacksmithing Shop Manual β€” every basic operation as a one-page job sheet; Ilgen Forge Work β€” drawing, upsetting, bending and welding explained; TM 10-440 β€” heat colors, forging and welding in brief.

πŸ”© Which scrap steel to use

(Peace Corps Basic Techniques of Blacksmithing, p. 31)

Steel Found in Good for
Low carbon β€” won't harden Car body panels, most rebar (Rebar), nails, bolts, rail spikes (Railroad spike), pipe, drums Hooks, hinges, brackets, tongs, anything that bends instead of cuts. Forge-welds easily.
Medium carbon β€” hardens Leaf and coil springs (Coil spring), axles, torsion bars, shock-absorber rods Chisels, punches, hammers, axes, hoes, pry bars, springs. The best all-round tool stock.
High carbon β€” hardens hard Old files, saw blades, drill bits, dies, bulldozer blades Knives, scrapers, wood chisels, plane irons β€” tools that must hold a keen edge.

Sources disagree on springs. The Peace Corps puts car springs, axles and torsion bars in the medium-carbon group; Practical Action calls coil springs, leaf springs and torsion bars high carbon. Test each piece and treat springs as hardening steel either way. Practical Action also warns that rebar often has a bit more carbon than true mild steel. (Practical Action, p. 5)

Spark streams from a grinding wheel: long plain streams from low-carbon steel, bushy streams full of bursts from high-carbon steel, and short broken streams from gray cast iron At the grinder (wheel on the right): low-carbon steel throws long, plain streams; high-carbon, bushy streams full of bursts; gray cast iron, short streams (Navy Steelworker, p. 23).

Spark testing, Leaf spring. More pictures: Carbon steel.

πŸ“š Go deeper: Peace Corps manual, scrap identification β€” what's in scrap and how to test it; Navy Steelworker Vol 1 β€” spark and chip tests with pictures; Practical Action Blacksmithing brief β€” mild, medium and high carbon steel from old vehicles.

πŸ§ͺ Hardening and tempering

  1. Anneal (soften) old steel before reshaping it cold or filing it: heat slowly to red, then bury it in dry wood ashes, lime or powdered charcoal and leave it until cold. (Selvidge, p. 56; Annealing)
  2. Harden: heat evenly to cherry red β€” rule of thumb: just past the point where a magnet stops sticking to it β€” and quench.
    • Plain carbon steel (springs, files, most scrap): water or brine (about ΒΎ lb salt per gallon) cools fastest and most evenly. Thin or very high-carbon pieces (files, knives) can crack in water β€” warm oil (80–150 Β°F; vegetable oil works) is gentler. (Steelworker, pp. 35–36)
    • Alloy steels: oil only.
    • Keep the piece moving in the quench. Steam and gas bubbles otherwise cling to it and leave soft spots, which can later crack or warp. (Selvidge, p. 57; Steelworker, p. 35; a quench tank; Quenching)
    • The steel is now glass-hard and brittle β€” temper it right away, before it's fully cold. The Navy Steelworker manual takes parts out of the quench at about 200 Β°F β€” still too hot to touch β€” rather than letting them cool through the "cracking range" below that. (Steelworker, p. 31)
  3. Temper: polish a spot bright with sandpaper or a stone, then reheat gently (over the fire, on a hot plate, or in an oven) and watch the colors run. Quench when the edge reaches the color you want:
Color About Use
Pale yellow 430 Β°F Engraving and lathe tools, scrapers
Straw 460 Β°F Taps, punches, dies, knives for a very hard edge
Brown-yellow (deep straw) 500 Β°F Wood chisels, drills, plane irons, hammer faces
Purple 530–540 Β°F Light cold chisels, shears, axes
Blue tinged with purple 550 Β°F Ordinary cold chisels
Blue 570–600 Β°F Springs, picks

The further toward blue, the softer and tougher. Books disagree a little β€” one old table puts most chisels and knives at light blue β€” so test your tool and adjust. (Bacon, p. 263; Selvidge, p. 59; TM 10-440, p. 26)

One-heat method for chisels and punches: heat the working end to cherry red, quench only the tip inch or so (bob it up and down), pull it out, quickly polish the tip, and watch the heat from the shank run colors toward the edge. When the right color reaches the edge, quench the whole tool. (Steelworker, p. 34; Selvidge, p. 58)

Three steps: a chisel's working end heated cherry red, only its tip dipped and bobbed in water, then color bands of blue, purple, brown and straw creeping toward the polished edge One heat for a cold chisel: the colors creep from the hot shank to the edge, and you quench it all when purple arrives; real colors vary with the light (a diagram drawn for this guide).

Many pieces at once: temper them in a pot of oil over the fire with a thermometer instead of by color β€” steadier and more even. (Bacon, pp. 263–264; tempering kettle with its lid)

If the tool doesn't work right:

Problem Likely cause Fix
Edge chips or breaks in use Too hard Reheat gently to the next softer color and quench (Selvidge, p. 59)
Edge bends or dulls fast Too soft β€” tempered too far, or never got hard Re-harden and temper less (rule of thumb)
File still bites after quenching Low-carbon steel, or not hot enough Test the steel; heat to full cherry red
Soft spots Steam pockets in the quench Move the piece in the quench; use brine
Cracked in the quench Too hot, quench too harsh, thick-and-thin shape, sharp inside corners Harden at cherry, not hotter; use oil for thin or high-carbon pieces
Warped Uneven heat or uneven entry into the quench Heat evenly; plunge straight in, thick end first (Drew, p. 64; an axe going in thick part first)

Tempering colors. More pictures: Hardening, Heat treating.

πŸ“š Go deeper: Bacon Forge Practice and Heat Treatment of Steel β€” temper colors and oil-bath tempering; Woodworth Hardening, Tempering, Annealing β€” deep detail on heat-treating tools; Navy Steelworker Vol 1 β€” annealing, hardening, quench media; Selvidge β€” annealing, hardening and tempering job sheets.

πŸ› οΈ Making basic tools

Sharpening a plow share β€” gardens and fields here depend on it (Drew Farm Blacksmithing, pp. 62–64; drawing out a share's edge; Ploughshare):

  1. Use a round-faced 2½–3 lb hammer. Draw the edge out by hammering the top side while the bottom lies flat on the anvil.
  2. Don't burn the edge while heating β€” it's thin and heats fast.
  3. If the point bends over, rest the edge on a hardwood block, not the anvil, while you drive it back.
  4. Harden a good-steel share at full red, plunging it thick side first into water or brine. For stony ground, leave it less hard so it doesn't chip.
  5. A worn-out point can be replaced by welding on a piece of old plow steel (not a rasp β€” too high in carbon to weld easily), using borax as flux. Practice on scrap first. Skip the old book's chemical hardening powder.

πŸ“š Go deeper: Peace Corps manual β€” axe, hoe, tongs and hammer projects; ICS Tool Dressing β€” reforging and re-tempering worn tools; Drew Farm Blacksmithing β€” farm repairs, chisels and plow work; Richardson Practical Blacksmithing Vol 2 β€” tongs and shop-made tools.

πŸͺ“ Keeping hand tools working

Hanging an axe handle (USFS An Ax to Grind):

The hang of an ax: heads set too open and too closed, and a properly hung ax laid flat touching the table one third of the way from the heel Laid flat, a well-hung ax touches the table a third of the way from the heel (An Ax to Grind, p. 24).

Sharpening:

Edge angles for digging and trail tools (USFS Handtools for Trail Work):

Tool Bevel
Axe About 25Β°, slightly convex, fan-shaped 2–3 in back
Pulaski Axe blade like an axe; adze (grub) blade with about a β…œ-inch bevel (p. 25; drawing)
McLeod and draw hoes 45Β° on the outside edge; no need to hone (pp. 26, 28; hoe drawings; McLeod)
Mattock grubbing blade 35Β° on the underside (p. 27; drawing)
Shovel About 45Β° on the top (inside) face, filed from below the foot rest to the point (p. 29; blade shapes)
Carpenter's adze 30Β° on the underside, then whetstone (p. 46; Adze)
Digging bar Keep the factory bevel (p. 30)

Hammers and grinders (Army TM 9-243 Use and Care of Hand Tools):

Axe, Pulaski, Mattock, File, Whetstone.

πŸ“š Go deeper: USFS An Ax to Grind β€” hanging and sharpening axes step by step; USFS Handtools for Trail Work β€” using and sharpening digging and cutting tools; Disston Saw, Tool and File Book β€” jointing, setting and filing hand saws; TM 9-243 β€” Army care and repair of every common hand tool.

πŸ–ΌοΈ Pictures & diagrams

Look before you try it. πŸ–ΌοΈ = drawings in the books on this drive; πŸ“· = photos in the offline Wikipedia.

Forge, fire and anvil

Forging operations

Steel and heat treatment

Making tools

Axes and hand tools


The old books use coal forges and some chemicals now known to be dangerous (cyanide for case-hardening, asbestos). Use their methods, not their chemicals.

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