[TheForge] New student progress report.

[Jerry Frost]

----- Original Message -----
From: "D.E. (Donn) Barnes" <donn@phudpucker.com>
To: <theforge@mailman.qth.net>
Sent: Friday, July 18, 2003 11:04 PM
Subject: RE: [TheForge] new student


... Thrifty, Brave, Clean and Reverent ...

Donn



Yes indeedy do, Donn. ABSOLUTELY! <grin>

We had our second session this saturday and I'm left with a big sappy grin.

If Lindsey decides to take up smithing as a profession we have some serious
competition ahead of us friends. I can only hope she does decide to join us
in the art.

Last saturday I had to call breaks about every 20-30 mins as she tired. This
wasn't so much from lack of strength as experience. In attempting to control
the hammer and tongs she was keeping way too tight a grip; muscle fighting
muscle is exhausting. This weekend was a vast improvement, true to her word
she'd spent time last week working out with a hammer and wood block,
practicing her grip and technique. This weekend she was more relaxed with
better control and putting a lot more force into her blows. We started
around 10:30am and I didn't call the first break till 1:30pm. After lunch we
continued till she finished up around 4:30pm.

We only have a few sessions together before she's off to her next school in
Virginia, August 19th. <sigh> so I'm a bit pressed to jam the basics into
the few projects we have time for. Last weekend's leaf hook was a good
start, it covered a couple basic draws, a scroll, bending, truing up and a
little decorative chasing. It's also something a beginner can complete in a
couple hours. A finished first project is important.

Today she decided on making a toasting fork. This was acceptable though I
would've preferred something with more new ground for her. Still it's a good
project as I could set it up with several new things for her to learn. At
first I was going to have her slit the tines but after demoing the technique
I changed my mind and offered her the chance to fail spectacularly with a
shouldered draw and forge welded loop instead. In describing the technique I
told her there was a very good chance she would ruin the piece in the
attempted weld. Her choice.

To paraphrase her reply, 'No problem I don't expect to get everything right
the FIRST time.' Geeze it did my heart good when she emphasized "FIRST"; no
surrender for this gal. <grin> So we dove on in.

Before we actually started on the fork I had her chisel and hot set split
the end of a bar and upset the end of another for the experience. I think
it's important to illustrate exactly why it's called . . . UPSETTING!
<grrrrr>

We started with 3/8" sq. I had her do a shouldered draw to half it's
thickness, maintaining the 3/8" width for about 5" on one end. Then she
scarfed the end and top of the shoulder to recieve the weld, looped it over
on itself and cleaned it up preparatory for the weld. Wanting to give her
the best chance of success I could I had her take emery cloth to the scarfs
instead of just good a hard brushing. After she shined the scarfs nicely I
had her close it up cold with about a 3/4" lap and start heating. We fluxed
with straight borax at a bright red and brought it to welding heat.

When I'd explained the whats and whys of scarfing I'd gone over whats and
whys of the hammering pattern and weight of blows to use as well so when it
was ready so was she. With me hoovering <grin> she made the weld, refluxed
and returned it to the forge for the second welding heat. On the second heat
she refined and drew the join to an even 3/8" sq. to match the rest of the
bar, brushed it clean and quenched it so we could examine the weld.

It was beautiful. I deliberately didn't have her feather the end of the
scarf to make an invisible weld. I described the process but we both agreed,
she wanted clear evidence of her first forge weld. Except for the end of the
lap and the crux of the tines the weld was just plain invisible. The next
step was the real test; she twisted it to about 35* +/-. Except for the end
of the lap and crux it's still invisible. Bloody perfect. <VBG>

With a successful weld we were home free. She drew the other end to a nice
long 5" +/- tapered point, bent it 90* at the base and put a helical scroll
on it, like a sideways pig's tail. The idea behind the pig's tail finial is
weight. She plans on taking it kayaking and understandably doesn't want to
pack 30"+ of 3/8" steel bar along. The pig's tail scroll is to recieve a
stick extension handle for campfire use.

Next she cut the end of the welded loop and drew out the tines. I imediately
realized I should've held off having her scroll the pig's tail finial as it
made holding with tongs more difficult. Still, it was a good thing as it
illustrated perfectly how blacksmithing is an ongoing learning curve, no
matter how long you've been practicing. After numerous heats she had two
nicely tapered and shaped tines.

With me holding and Lindsey wielding the brush we shined it up then took it
into the house for an oven baked olive oil finish. (Just what I wanted to do
on a mid 80's day; run the oven at 400*f. in the already TOO hot house.
<sweaty sigh>)

Well, Lindsey's second session project is a nicely done, golden tan, Pig's
tail toasting fork.

We're both justifiably pleased as can be.

To date Lindsey's successfully done: Tapered draws, lateral/spreading draw,
uniform shouldered draw, upsetting, scrolling, bending, twisting, hot
cutting, hardy and set, slitting/splitting, chisel and hot set,
veining/chasing, forge welding and finishing.

I'll have a couple pics tomorrow or the next day.

To the lucky guy(s) in the vicinity of Virginia, her next port of call, who
get the privelege of taking over her training. . . This is a student that
will make you look good!

I'm a lucky guy.

Frosty
------------------------
If it ain't forged
it ain't real.
Wrought iron is.
The FrostWorks

Meadow Lakes, AK.