Gas Forge Burner ?'s

[Grundsau]

Last winter I had the notion to start blademaking and then got hit with some kind of major flu. Didn't get my stride back till after Christmas and then remodeling projects etc kept me away from blade making all Winter. Being a senior portrait photographer, our busy season starts in April and goes gangbusters thru the Fall.
I've been reading the forums off and on all Summer and now that our busy season is slowing down figured I'd try to build up a gas forge.

I did a search thru the site for Trex burners and didn't really find what I'm looking for. Maybe someone can help.
Was given a 40lb propane tank aways back to make a gas forge out of.
Originally thought about a Whisper Daddy III which would cost a bit more but its ready to go..

The tank size is roughly 16" long by 14.5" wide. When 2" kaowool is added that should bring the ID down to 10".
I'd like it to reach welding temps and hopefully there is enough juice to weld up a billet.
This forge will also be used for decorative ironwork and large openings will be helpful. Maybe I'll need to block them down a bit for billet welding.

Would I need two T-rex burners or just one for this set-up?
Was thinking of having the ability to turn off one burner for small stock and run two burners when welding.
What other valves should I look for besides ball valves for each burner?

Here's my shopping list for now:

2 - Trex burners
2"of Kaowool
Satanite over Kaowool
ITC-100 over Satanite
Needle valve (Not sure what type)
Armored hose to 100lb propane tank located outside of the shop for safety.

Let me know if there's anything else you may find helpful.

thanks for your help,
Allen

[TikTock]

Try this link:
http://www.indiangeorgesknives.com/b...g_a_forge.html

IG's forge is a basic air blown burner. I got the chance to see and use them first hand last weekend. They can do anything. We were welding up cable damascus with them all day long. If you build it just as he describes with a hard firebrick floor, flux is not a problem either. He said the last time he refinished one, the floor had 3/4" of flux on it with no damage whatsoever.

[Omega]

granted i know not that of which i speak, but isnt a 1/8 hole a little big for the gas outlet hole?


bill

[TikTock]

Beats me!
Seemed to work pretty flawlessly for forging and welding up damascus, though....

[Ray Rogers]

I recently built a forced air forge similar to the one pictured above. The outlet in mine is simply a 1" pipe and it works fine too. I think the great thing about forced air forges is that nearly ANYTHING will work as long as the fuel and air get mixed well....

[Grundsau]

Thanks guys for the replies. Forgot to mention this is going to be a venturi set-up. The ability to keep forging after the power goes off is a definite plus. We often lose electric during the Winter and sometimes during the Summer where we're located.
Allen

[KandS_KNIVES]

Take a look at Ron Reils site, alot of different burners. I have built just about all of them, but the improved sidearm burner seems to work the best of the venturri type. With a little engineering this type burner can be used as a forced air, as well as venturri.

Ken Beatty

[Grundsau]

Hi Ken, I had printed off all the info to be found from both the Ron Reil and Hybrid Burner websites.
I'd really like to know if 2 - 3/4" T-Rex burners are enough or too much for a 40lb tank to reach welding heat?
Someone out there knows the answer. :cool:

Thanks anyways for the suggestion.

Allen

[KandS_KNIVES]

In a word yes, but a 1" or 1.25 would do it for you too. I have found that multiple burner venturri burners seem to have problems quite abit.

Ken Beatty

[rhrocker]

Talk to Rex Price. He's the one that knows about the T-Rex's. He designed and now makes them.

[Grundsau]

Thanks again for your help. I had emailed Rex with questions and received no response.
While searching thru Google, I found some info on gas forge kits.
For the time (which I don't have a lot of) and effort it will take to locate parts, plus the nagging questions of "am I doing this safely?", these kits have everything and are ready to be built.
The forge outlined in red looks like a winner.

Below is a price list of our LP Gas Forge Kits and Forge Building
Supplies. If you are not sure of what kind of forge or how many burners
you need, I'll be glad to explain the differences for you. Feel free to
call me at the number listed below.

The kits include just about everything you'll need to build your forge.
All of the forge kits are supplied with the parts to build 3/4 inch high
performance burners and "Fuel Saver" valve manifolds. You may want to
add a cart and forge some interesting door hardware to show off you
forging skills. But that can be added later. We now also offer CNC
plasma cut end plates with door cutouts as an additional option.

We stock a large inventory of other parts and custom roll steel forge
and foundry shells. We can also do any necessary cutting, welding and
machining if you are not set up to do it yourself.

I can figure the shipping cost for you if you email me your shopping
list and zip code. We accept check or money order. We can now also have
Visa and Master Cards processed for an additional three percent
processing fee.

Thanks,

Jay Hayes
C.J. Products Inc. Phone: (304) 269-6111
100 Christmas Place New Email: jay@hrea.coop
Weston, WV 26452



Price list as of 10/1/05

SUPER WIDE CLAM SHELL FORGE KITS

Three Burner Super wide Clam Shell Forge
16" W x 12" H x 24" Long, 3 burner LP gas Forge Kit,
w/ Fuel Saver Valve Manifold, 3'' Ceramic Fiber liner, Super duty
floor bricks, ITC-100, LP Gas Regulator and Hose.
with 11ga. steel shell $465.95
Drilling and tapping of 27 holes in burners and burner supports, add $25.00
CNC plasma cut end plates with door cutouts, add $40 (pair)

Two Burner Super Wide Clam Shell Forge
16" W x 12" H x 18" Long, 2 burner LP gas Forge Kit,
w/ Fuel Saver Valve Manifold, 3'' Ceramic Fiber liner, Super duty
floor bricks, ITC-100, LP Gas Regulator and Hose.
with 11ga. steel shell $400.95
Drilling and tapping of 18 holes in burners and burner supports, add $18.00
CNC plasma cut end plates with door cutouts, add $40 (pair)

Single Burner Super Wide Clam Shell Forge
16" W x 12" H x 12" Long, Single burner LP gas Forge Kit,
w/ Fuel Saver Valve Manifold, 3'' Ceramic Fiber liner, Super duty
floor bricks, ITC-100, LP Gas Regulator and Hose.
with 11ga. steel shell $285.95
Drilling and tapping of 9 holes in burners and burner supports, add $9.00
CNC plasma cut end plates with door cutouts, add $40 (pair)


SUPER WIDE OVAL FORGE KITS

Three Burner Super Wide Oval Forge
16" W x 12" H x 24" Long, 3 burner LP gas Forge Kit,
w/ Fuel Saver Valve Manifold, 3'' Ceramic Fiber liner, Super duty
floor bricks, ITC-100, LP Gas Regulator and Hose.
with 11ga. steel shell $440.95
Drilling and tapping of 27 holes in burners and burner supports, add $25.00
CNC plasma cut end plates with door cutouts, add $35 (pair)

Two Burner Super Wide Oval Forge
16" W x 12" H x 18" Long, 2 burner LP gas Forge Kit,
w/ Fuel Saver Valve Manifold, 3'' Ceramic Fiber liner, Super duty
floor bricks, ITC-100, LP Gas Regulator and Hose.
with 11ga. steel shell $377.95
Drilling and tapping of 18 holes in burners and burner supports, add $18.00
CNC plasma cut end plates with door cutouts, add $35 (pair)

Single Burner Super Wide Oval Forge
16" W x 12" H x 12" Long, Single burner LP gas Forge Kit,
w/ Fuel Saver Valve Manifold, 3'' Ceramic Fiber liner, Super duty
floor bricks, ITC-100, LP Gas Regulator and Hose.
with 11ga. steel shell $259.95
Drilling and tapping of 9 holes in burners and burner supports, add $9.00
CNC plasma cut end plates with door cutouts, add $35 (pair)


STANDARD FORGE KITS

14 '' OD x 24'' Long, 3 burner LP gas Forge Kit,
w/ Fuel Saver Valve Manifold, 3'' Ceramic Fiber liner, Super duty
floor bricks, ITC-100, LP Gas Regulator and Hose.
with 11ga. steel shell $420.95
(with out steel shell $360.95 )
Drilling and tapping of 27 holes in burners and burner supports, add $25.00
CNC plasma cut end plates with door cutouts, add $35 (pair)

12'' OD x 24'' Long, 3 burner LP gas Forge Kit,
w/ Fuel Saver Valve Manifold, 3'' Ceramic Fiber liner, Super duty floor
bricks, ITC-100, LP Gas Regulator and Hose.
with 11ga. steel shell $385.95
(with out steel shell $330.95)
Drilling and tapping of 27 holes in burners and burner supports, add $25.00
CNC plasma cut end plates with door cutouts, add $30 (pair)

12'' OD x 18'' Long, 2 burner LP gas Forge Kit,
w/ Fuel Saver Valve Manifold, 3'' Ceramic Fiber liner, Super duty floor
bricks, ITC-100, LP Gas Regulator and Hose.
with 11ga. steel shell $332.95
(with out steel shell $287.95)
Drilling and tapping of 18 holes in burners and burner supports, add $18.00
CNC plasma cut end plates with door cutouts, add $30 (pair)

12" OD x 12" Long, one Burner LP gas Forge Kit,
w/ Fuel Saver Valves, 3'' Ceramic Fiber liner, Super duty floor bricks,
ITC-100, LP Gas Regulator and Hose.
with 11 ga. steel shell $225.95
(with out steel shell $190.95)
Drilling and tapping of nine holes add $9.00
CNC plasma cut end plates with door cutouts, add $30 (pair)

10'' OD x 12'' Long, one burner LP gas Mini Forge Kit,
w/ Fuel Saver Valves, 2'' Ceramic Fiber liner, Super duty floor bricks,
ITC-100, LP Gas Regulator and Hose.
with 11 ga. steel shell $202.95
(with out steel shell $172.95)
Drilling and tapping of nine holes add $9.00
CNC plasma cut end plates with door cutouts, add $25 (pair)


BURNER and VALVE MANIFOLD KITS

High Performance LP Gas Burner Kit, with mounting tube (undrilled) $28.50
(drilled and tapped $37.50)

Budget Burner Kit (undrilled) $23.70
(Drilled and tapped $26.70)
(the basic burner parts, without mounting tube and extra brass fittings)

Fuel Saver Valve Manifold kit for a Single Burner Forge,
w/LP gas Regulator, Gauge, and 5ft LP Gas Hose & fittings $74.65
(burner must be ordered separately)

Fuel Saver Valve Manifold Kit for a Two Burner Forge
w/LP Gas Regulator, Gauges, and 5ft LP Gas Hose & fittings $104.59
(burners must be ordered separately)

Fuel Saver Valve Manifold kit for a Three Burner Forge,
w/LP gas Regulator, Gauges, and 5ft LP Gas Hose & fittings $119.80
(burners must be ordered separately)


PARTS

LP gas regulator $28.95 ea.
POL tailpiece $3.95 ea.
LP gas hose x 5 ft $11.75 ea.
(for longer hoses add $1.25 per additional foot)
3/8 MF x 1/4 MPT (to adapt hose) $ .95 ea.
3/8 FPT x 1/4 MPT (to adapt hose) $ 1.00 ea.
0-30 psi pressure gauge $6.75 ea.
LP Gas Quick Disconnects (M&F) $14.50 set
1/4 brass ball valves $6.95 ea.
1/4 brass needle valve $3.50 ea.
1/4 brass tees $1.65 ea.
1/4 brass elbows $1.45 ea.
1/8 brass elbows $.95 ea.
1/4 x 1 1/2 brass nipples $.90 ea.
1/4 x 2 brass nipples $1.25 ea.
1/4 x 3 brass nipples $1.85 ea.
1/4 x 4 brass nipples $2.55 ea.
1/4 x 6 brass nipple $3.99 ea.
3/8 compression x 1/4 MPT $ .75 ea.
3/8 compression x 1/8 MPT $ .85 ea.
3/8 copper tubing $ .75 ft.
1 1/2 x 3/4 bell reducer (undrilled) $6.15 ea.
1 1/2 x 3/4 bell reducer (drilled & tapped) $9.15 ea.
3/4 x 8 black nipples $1.90 ea.
Brass Orifices (specify drill size) $1.85 ea.
1/8 x 2 1/2 nipple full thread $2.50 ea.
Choke Plates $3.50 ea.
1/8-27 NPT nuts $ .15 ea.
1 x 3 nozzle w/taper (machined steel) $7.50 ea.
1 x 3 nozzle w/taper (machined stainless) $9.00 ea.
Burner mounting tubes (undrilled) $3.00 ea.
Burner mounting tubes (drilled & tapped) $9.00 ea.
ITC-100 coating $26.95 Pint
Ceramic Fiber Insulation 8#, 1", 2400 deg. $3.25 sq ft
Ceramic Fiber Insulation 8#, 2", 2400 deg. $6.50 sq ft
Ceramic Fiber Insulation 8#, 1", 2700 dig. $5.80 sq ft
Ceramic Fiber Insulation Board 8#, 1" $12.50 sq ft
Super Duty 1 1/4 x 4 1/2 x 9 Floor Bricks $4.50 ea.
Super Duty 1 1/4 x 6 x 12 Floor Bricks $7.00 ea.
1 x 1 1/4 x 1 1/4 IFB Support Blocks $ .50 ea.
1 x 1 1/4 x 2 IFB Support Blocks $ .75 ea.

All prices plus shipping. Prices are subject change.
Ceramic fiber insulation blanket and board comes 24 inches wide
and is sold by the square foot.

[B.Finnigan]

Tiktoc, What does the flex hose do that comes off of the secondary blower? I am guessing that it deflects some of the heat from the front of the forge? Inquiring minds want to know.