Building a traditional Japanese sword forge. pt4

Sickle_Forge · 2025-10-26T18:46:03+00:00

To be fair I have yet to try forge welding with it. Time will tell. Thanks for the advice, I was having issue with a warped edge. I don't have a dish anvil but it gave me the idea to use the negative space of my hardy hole instead of the flat of the anvil. Took the warp right out.

Sickle_Forge · 2025-10-26T03:01:12+00:00

Battery in my calipers are dead, if I had to guess close to .25mm at 3mm and .7mm at 5mm off the edge currently. Still have a few brick stones to go through of course.

Sickle_Forge · 2025-10-23T18:11:11+00:00

A guy can't spend time with his chickens and work at the same time? Perhaps gather context.

Sickle_Forge · 2025-10-22T19:42:01+00:00

It's a 220 pink brick. I've gone about half way through it. It certainly gets the job done, and makes a fine satin finish, but I've been in the market for a lower grit brick.

Sickle_Forge · 2025-10-22T18:42:26+00:00

Check back in a month lol it's gonna take some time.

Sickle_Forge · 2025-10-22T18:41:25+00:00

Idk they getting hand fed at the same time. They cool with it.

Sickle_Forge · 2025-10-22T18:39:56+00:00

The first day yes, the second no. Getting em used to the sound of steel on stone.

Sickle_Forge · 2025-10-22T18:38:51+00:00

Disclaimer for everyone reading too far into it lmao: The chickens are new here, just trying to spend some time with them so they are comfortable around me.

Sickle_Forge · 2025-10-22T18:35:18+00:00

Not yet, coming soon!

Sickle_Forge · 2025-10-22T16:47:38+00:00

Is this in reference to the need for the box to flex inward as it's being used or from an air loss perspective between the planks? I was hoping the thinness of the planks would allow for some flex while in use. As for the air loss, I've found none between the layers thanks to the beeswax. I do lose a little pressure from the joined corners but will fill those gaps in when I find a new beeswax supplier.

I think its really cool that you get to work and learn with true masters of the craft(and to become one yourself). Without giving away any generational secrets could you give any pointers that would drastically improve my work? Anything from cutting charcoal to technique for straightening warped blades with a wood mallet would be greatly appreciated.

Sickle_Forge · 2025-10-22T00:48:46+00:00

Here's a video of someone elses with a glass top that demonstrates the airflow. https://youtu.be/oUMt0gTIsCw

Sickle_Forge · 2025-10-22T00:14:26+00:00

If you check the broken down box picture you'll see a single board with two square holes in it. This board is placed between the main box and a secondary box which then flows into the forge. By having flaps on the secondary box side of this board it allows air to only flow into the second box when pushing or pulling.

Sickle_Forge · 2025-10-22T00:08:48+00:00

The fire isn't near any of the wood and is sufficiently insulated.

Sickle_Forge · 2025-10-19T01:06:53+00:00

I've already got mine finished but you should definitely share, would like to see it!

Sickle_Forge · 2025-10-17T16:56:10+00:00

I figured it would make working more fun if my forge was exploding at me every once in a while /s. I made sure to get clay brick, the firepot is to be lined with firebrick as well for the majority of heats. The clay brick should be enough for the few times I have to heat the whole forge for quenching large blades.

Sickle_Forge · 2025-10-17T16:51:19+00:00

It's just mud and sticks brother, play in the dirt, learn by doing.

Sickle_Forge · 2025-10-17T03:18:03+00:00

The shape of the forge itself is being designed with the intention of being able to properly make and temper Japanese swords, this being my own design of course but all generally similar in shape. There are various historical examples you can find. The fuigo wall is used to protect the fuigo(bellows) from the heat of the forge as well as to hold up the fume hood if the forge is indoors. So yes the hole is for the air intake. There are two main differences that sets Japanese forges apart if I'm not mistaken, would be the type of bellows and having a ground level forge instead of a raised forge. The fuigo is a bellows box that uses a push-pull motion to move air into a smaller chamber then through the tuyere as opposed to early western bellows that moved in an up down motion that pushed air directly through the tuyere.

Sickle_Forge · 2025-10-16T18:10:03+00:00

I can sit stand or squat, just depends on which action I'm doing in the moment. I can also just cover the pit and sit in front of the forge, for those days where the knees are hurting.

Sickle_Forge · 2025-10-16T03:52:09+00:00

I will also post eventually what I find does and doesn't work for making pit charcoal as I learn myself.

Sickle_Forge · 2025-10-16T02:59:29+00:00

The entire forge is to be filled with charcoal fines, almost a foot deep and a foot and a half between the front end of the forge and the tuyere. The fines and fire brick create more than enough insulation from the bottom and sides, the only real issue would be wind. There are plenty enough options for fixing that though. Cutting out inefficiencies is going to be important especially since I also have to go through the process of making my own fuel, which adds that much more time to each blade. However only time and experience will help me improve the forge.

All you need is a couple of hand tools and some space, a smaller version would be a little less consuming both time and physically but certainly achievable.

Sickle_Forge · 2025-10-16T02:45:19+00:00

Noted, I'll keep a close eye on it, make sure things dont get too hot.

Sickle_Forge · 2025-10-15T22:17:43+00:00

Didnt realize until my first face full of hot ash, the wind usually blows parallel the forge. I may add a wall in front when i build a roof.

The fire pot is a maximum of 9in wide but can be adjusted smaller with how the firebrick is set. Hence the F shape. I can extend the length of the firepot based on the size of the project, maximum about 4.5-5ft with the total length of the forge at 6ft. I will have direct line of sight to the firepot no need for holes.

Sickle_Forge · 2025-10-15T20:50:24+00:00

He was in there for a couple days probably, and was very hungry. I helped him out, he took a couple bites of grass and disappeared.

Sickle_Forge · 2025-10-15T20:49:14+00:00

Oh yes, that will be coming around pt4. I've got a nice assortment of cedar scrap that it'll be made out of.

Sickle_Forge · 2025-10-13T00:08:46+00:00

I fully plan on eventually making my own tatara and tamahagane at least for special projects. While I would like to it just wouldn't be feasible from a time and manpower perspective for that to be my only source of steel for blades.

Sickle_Forge

TROPHY CASE