Forging my own stock with the Massey

A video of me forging my own stock, just like a real blacksmith! I had to make my own 40 x 20 mm from 30 mm square because I waited until the last minute to order my material and it didn't show up in time.

Forging a set down with the Massey

Here is a video of me forging the set downs for my gate elements using the Massey and the Blacker. The method came from the Lillico book and some trial and error test pieces. In later pieces I forged down the section using a set black tool before moving over to the Blacker.

Forging a halving joint on the Massey power hammer.

Here is a quick video of me forging a halving joint for my gate project. The material spread nicely and the joint ended up looking very good.

Drifting a big hole on the Sahinler power hammer.

Here is a video I made of drifting a hole out from round to tapered octagon for flypress weights. I got the method from a video of Claudio Bottero punching and drifting a hammer eye. As you can see in the video, the method is trial and error. It ends up working quite well in the end.

3DSP Samples

Here are some of the samples I have made for my 3DSP project. All samples have been made using the power hammer with minimal hand work with the exception of the tooling. 

Leaf hammer forged from 25 mm square EN9 high carbon steel. The hole was punched by hand and the cheeks were drawn out on the fullering dies on the power hammer. All necking and forging of the faces was done using a broad fuller and striker. 

Rodded chisel punch forged from EN9 high carbon. The hole was punched and drifted by hand, and everything else was done using the power hammer. 

Texture and spread sample forged from 5 diameter pipe section. Half of the pipe was compressed and forged under the fullering dies, while the other half was untouched.

Another view of the same sample.

Here is a close up shot of a sample that I ended up incorporating into my gate for design development. It is a 40 x 12 mm flat that has been heavily fullered on edge so that it upsets the edge of the material while necking it in. It has to be done slowly and very hot with the finishing work done very cold. This creates a natural valley in the center of the piece that I really like. The best part about it is that the most interesting bit of the sample has been created without any direct hammer contact. 

Here is part of my gate for design development that uses side set tooling to set down material under the power hammer.

A close up of the set down. Please view the video for a full demonstration of how it was done.

Side set tool forged from spring steel. This is the tool I used to do the set downs in the above sample.  I took this design from the videos by Toby Hinkman. I also looked at the Lillico book for inspiration.

Cut off tool forged from spring steel. 

This sample plays with the possibilities of set downs and material isolation.

Punches made from EN9 high carbon tool steel. All three were forged smith and striker using mostly the flatter.

This is a sample using an interesting spring swage that I found on the rack. It has a single round fuller on top and two round fullers on bottom. 

The opposite side of the same sample.

An interesting finial sample made using the side set tool to isolate the end of the bar on two sides. The end was then squashed on the blacker mechanical hammer.

A sample using the same spring swage as the sample above. 

Made using the side set tool to isolate material then a flat block tool to forge down the center area.

Floral study using the fullering dies on the Kugn power hammer.

Box section that has been forged down using the fullering dies on the Kugn hammer. 

The other half of the same sample cut off on the bandsaw.

Albert Paley Forging Videos

Here is some video I shot while at his residency at Steneby School in Sweden. While working there, he did almost all work on a Beche 125 kg power hammer with flat dies. I never saw him use any tooling, swages, etc. He really shows the versatility of flat dies to achieve sculptural form and texture. All video was shot with my iphone so the quality is not great, but it still illustrates the work.

More pics of power hammer work.

Here some more pictures of free form power hammer forging used in different pieces of work. These pieces really exploit the plasticity of the material. 

Gate Progress

Excerpts from "Blacksmith's Manual Illustrated" by J.W. Lillico

In my quest to learn more about power hammer techniques, I was introduced to one of the most useful books I have ever read. Blacksmith's Manual Illustrated was written by J.W. Lillico in 1930. Mr. Lillico wrote this book as a compilation of tips and tricks acquired over a long career in the trade. It is complete with diagrams and descriptions for all sorts of blacksmith work from the anvil to the power hammer. The book emphasizes precision and efficiency.

Here are some scans of my favorite tooling diagrams and descriptions:

Power Hammer Tooling

Here are some images of power hammer tools I have come across. Most of them are used in  the industrial forging industry. I find that most of the best top and bottom tools are used for industrial forging and then adapted to be used artistically.

All of the images below come from the Facebook profile of Roger Lund. Roger is an industrial blacksmith in Sweden.

Here is a cutoff tool used to hot cut bar under the hammer. Notice the slight recess in the bottom so that the metal is not totally cut through and flies across the shop. The end can then be twisted off. The handle is also bolted on so that it pivots and can come down square to the work without bending. I am sure this cuts down on vibration as well.

Here is a tong making bottom swage complete with a dimple to mark for the hole in the hinge plate. 

Here is a tenon swage with guides to ensure proper alignment.

A method of attaching swages to handles rather than welding. It involves drilling the swages out to 15 mm and inserting  12 mm bar that has been upset to 13-14 mm. You then run a round punch around the hole to secure the handle in. This apparently holds much longer than weld and reduces vibration up the handle.

More swage tools for making tong blanks. I will be making some of these soon.