The first forge / Three-burner propane

Forge Mk1.

The first forge I designed and manufactured: a three-burner propane forge serving daily blacksmithing lab use. Across almost two years, it has accumulated close to 2,000 hours at temperature and supported more than 400 students learning hot work.

Daytime view of Forge Mk1 — Forge Mk1 — burners, door mechanism, piping, and cart

Forge Mk1 operating outside the workshop

Completed forge with its door and burner assembly

Completed Forge Mk1 viewed from the side in daylight

Forge chamber and refractory opening at temperature

Forge in use

Forge Mk1 uses three propane venturi burners to heat a refractory-lined chamber. It was designed for repeated daily use in Purdue’s Blacksmithing Lab, including forging, heat treatment, and forge-welding work. Heavier refractory was chosen to withstand the wear of frequent use and reduce maintenance interruptions. Burner adjustment provides basic control of the forge atmosphere for different hot-working tasks.

Teaching

The forge was built to support a teaching lab where many students encounter blacksmithing for the first time. Its role extends from heating stock to supporting the full process: moving between forge and anvil, shaping material, and exploring heat treatment. A robust chamber and reduced maintenance downtime help keep the equipment available for regular lab sessions.

Discussing work in the blacksmithing lab

Using Forge Mk1 during a blacksmithing session

Students watching a blacksmithing demonstration

Original Forge Mk1 project update ↗

Overview

The design began with prototype venturi burners and machined injectors and venturi bodies. I formed the sheet-metal forge body, prepared the lining and wooden cavity mold, and cast the high-temperature refractory.

The refractory was dried and heat-cured before the forge entered service. The build photographs follow the burners, shell, lining, and completed forge.

Burner manufacturing

Prototyping and machining established the burner geometry before the shell and refractory assembly.

Body and refractory

The body, burner openings, and refractory lining bring the individual components into a working forge.

Manufacturing pictures

The forge body, burner openings, and door assembly during fabrication, before final lining and assembly.

Front view of the forge and door assembly

Forge shell and burner openings during construction