vol 29 no 1 - New England Blacksmiths

To discover, to help
New England
Blacksmiths
VOL. 29 NO. 1
Winter Edition
Our
31st
Year
1978-2009
Sent in your 2009 Dues Yet?
No? What are you waiting for!
Atlantic
Anvil by Mike Sarri in the ACBC Gallery
Coast Blacksmith Con-
Lots in this issue:
2 NEB Contacts
15 Mercier workshop @ D’Abate’s
24 Framing Square
3 Pres. Message & a new item
16=17 Cast Iron repair Question
25 Quick Heat Treat Chart
4 Around New England
18 Letter to Editor & Membership
Form
26=27 Jim’s Great Adventure
28 ABANA for you?
5=8 ACBC Report
9=11 ACBC Gallery
12 Spring Meet Preview
13=14 Assabet Highlights
Winter 2009
19 Power Hammer Guards
Needed
29 Tailgate
20=22 Charlie’s Challenge
23 Ashokan Bench
Visit us on line
www.newenglandblacksmiths.org
www.newenglandblacksmiths.com
Page 1
New England Blacksmiths
Most recent Contact information for NEB officers and directors
Owen Bostrom- President (10)
99 Chase Hill RD
Ashaway, RI 02804
Phone: 401-377-2611
obostrom@cox.net
.Bob Menard– Vice President (10)
56 Warren Ave. Suite 106
Portland, ME 04103
Phone: 207-878-2217
ballandchainforge@yahoo.com
Jim Crothers- Secretary (10)
953 Tuckertown RD
Wakefield, RI 02879
Phone
ride4782@ride.ri.net
Tim Blanchard - Treasurer (10)
1 Juniper Lane
Hallowell, ME 04347
Phone: 207-622-4685
timb88@roadrunner.com
Karen Sims, Membership Chair. (10)
337 Rope Ferry Rd
Waterford, CT 06385
860-442-3925
karensims@gmail.com
Marc Godbout, NH Rep. (10)
P.O. Box 1114
Derry, NH 03038
Phone 603-548-8771
marc@ironringforge.com
Taffy Case, NH Rep. (09)
1789 E. Madison Rd
Madison, NH 03849
Phone: 603-367-8225
taffysforge@yahoo.com
Fred Mikkelsen - RI Rep & Editor (09)
23 Waterman Dr.
N. Scituate, RI 02857-2036
phone: 401-647-3086
fred@trollshammerforge.com
John Nash- RI Rep. (10)
173 Fairfax DR
Warwick, RI 02888
Phone: 401-781-0558
The New England Blacksmiths, an affiliate of the Artists-Blacksmith’s Association of North America, is
devoted to the preservation and advancement of blacksmithing. Letters to the editor, articles, technical
tips, tools for sale, or other materials which furthers
these ends, will be considered for publication in this
newsletter.
Winter 2009
Richard Holman- ME Rep. (10)
195 Varney Mill Rd
Windham, ME 04062
Phone: 207-892-9511
rhholman@mactec.com
Ed Grove- Me Rep. (09)
828 Haley Town Road
Brownfield, ME 04010
Phone: 207-935-2262
engro828@pivot.net
Richard Spreda- VT Rep. (10)
55 B Mountain rd.
Stowe VT 05672
Phone: 802.253.7251
stowesmith@stoweaccess.com
James Fecteau- VT Rep. (09)
1735 Main Rd.
Huntington, VT 05462
Phone: 802-434-3871
fecteau@gmavt.net
Jay Cadero- MA Rep. (09)
54 William ST
Walpole, MA 02081
Phone
cadero@prodigy.net
Jack Daniel- MA Rep. (10)
70 Cinderella Terr.
Marstons Mills, MA 02648
Phone
jackadaniel@hotmail.com
David Hageman - CT Rep. (09)
6 Dickinson Rd.
Colchester, CT. 06415
860-267-0659
hagemanneb@yahoo.com
Mark Kellogg- CT Rep. (10)
49 Midland Rd
Windsor Locks, CT 06096
Phone: 860-627-0895
MKell9761@aol.com
Note: The number ( ) after each name
denotes the year of term expiration of
that Board Member.
Sign seen outside a US Bank
We can lend you enough
money to get you
completely out of debt
New England’s own Robert Frost
once said,
“A bank is a place were they
lend you an umbrella on a
fair day and ask for it back
when it begins to rain.”
May you prosper
in the New Year
FWM
Thanks to all
Contributors to this issue:
Add your name to this list
Become a newsletter contributor!
Jim Fecteau
Keith Leavitt
Ralph Sproul
Charlie Sedell
Photos of the ACBC courtesy
of Ralph Sproul, Jack Daniel
& Bill Clemens
Next newsletter deadline:
March 15th, 2009
The New England Blacksmiths disclaim any responsibility or liability for damages or injuries as a result
of any design, construction, manufacture, use or
other activity undertaken as a result of the use or
application of information contained in the newsletter of the New England Blacksmiths.
Page 2
New England Blacksmiths
Prez Mess January 2009
Hello everyone. Today is the second day of 2009 and Fred has again asked
me to write a message from the President. First of all I hope this finds you well and
not too depressed on the economics expected for the coming year. We are entering
a new political era soon and who knows what good things could come from that.
NEB remains pretty healthy from a financial point of view. Our investment in the
Fall Conference in New York actually returned us a nice profit. Ralph Sproul and
Bob Compton did a magnificent job representing NEB in planning that event. I
have asked Fred to print my management summary of the meet elsewhere in this
Newsletter. Our group remains active trading information and helping each other
learn our craft. We have some new members, and hopefully this Newsletter will remind you to send in
your $20 check to renew yours as well.
The outlook for this year is pretty good as well. The BOD has taken over the task of putting on the
Spring Meet at Brentwood. You may remember that Carl Close had volunteered to lead that event. After
working with a few key members on setting up the program, Carl and Susan became overwhelmed with family
matters that would tax any of us and asked us to continue on without them. The BOD and Brentwood Committee stepped up and the meet will go on as planned. Hopefully, Carl and Susan will be able to attend. See
more on this meet in the following pages.
Our Fall Meet will be at the home and shop of Jim Fecteau. Jim and the Green Mountain Crew are
well into planning what looks to be a great event in a neat spot. More on that can be seen in the Newsletter too
Thinking of Vermont reminds me that our auctioneer, Richard Spreda slipped on ice and fell recently
severely injuring his leg. He has undergone surgery and reports he is on the mend. If you think of it he would
probably enjoy hearing from you.
Over the year, Karen Sims has done a great deal to get our membership records in order and to put together a usable data base. That data base can be used to better understand who renews their membership, and
who doesn’t. From that maybe we will better understand why we have member turnover. Tim Blanchard
also had an outside audit performed on our NEB treasury books and all was found to be in order. I have a full
cast of officers and local state representatives, as well as an up to date web site, a webmaster, and a super
Newsletter editor (and administrative assistant to boot). What’s not to like?
Good luck, good health, good interesting work, and I hope you all prosper in this New Year.
Owen Bostrom, President, NEB
January 2, 2009
NEB New Item:
Our own Heavy Duty Fire Pots (50lbs) are available now!
Measure 9-1/2 x 12 inches
pricing structure;
Pot with a drawing of a recommended tyure $160.00
2 Holes drilled and tapped to accommodate the tyure,
handle extension attached to the
clinker breaker. $175.00
Pre-assembled tyure that easily
bolts on. $65.00
Prices subject to ME sales Tax;
About $8.00
Shipping to anywhere in the northeast $25.00
Contact Bob Menard (207) 878-2217
<ballandchainforge@yahoo.com>
Winter 2009
Page 3
New England Blacksmiths
Around New England
Maine
NEB Teaching Center @ Brentwood NH
Will be open and staffed on the following dates:
3/28—4/25—5/23
Contact Bob Gilbert (603) 642-5440
Connecticut
January 11 CBG invites the Southern Bunch and
others to the Driggs Blacksmith Shop at Mystic
Seaport 1:00 pm contact Bill Scheer for free admit
(860) 536-0679
Jan. 31st Falling Hammer Productions, Matt Parkinson, Peter Swarz-Burt and Jamie Lundell demo
knife & sword making plus power hammer use
from 1 to 4 pm 28 Main St in Oakdale, CT
March 21 CBG at the shop of Dave Hageman 284
S. Main St Colchester, CT from 10 am—4 pm
Contact Dave (860) 267-0659
April 4th, BSA Merit Badge Day at Dominion
Power Plant in Waterford, CT to work on Metal
Craft Badge–
contact Doug Van Verdeghem (860) 444-1894
Massachusetts
Jan 17—The Martell’s Metal Works “Back to Basics” with George Martell & Ron Picard, 36 Maple
Ave in Seekonk, MA from 9 am to 4 pm
Contact George (508) 761-9130
14th March 2009 - Berkshire Blacksmith Assoc.
at Greg Phillips’ Acorn Forge and Fabricating (A
Sure Sign) 9:00-4:00. Montgomery, NY. Shop
is located on left at #937 State Road. (845) 4575671. Greg and others will demonstrate CNC and
plasma cutting and forming of sheet metal, roses
and flowers. Bring samples of your work to show
and tell. TAILGATE SALES
Lucian Avery, Blacksmith Classes
Once again the Ball & Chain Forge will host
Brentwood North Program will be held on February 28 in Portland ME. This year's program features all new instructors and 4 new 90 minute programs. The day, for those who have not attended in
the past, consists of 4 different 90 minute sessions
that rotate thru the shop exploring different aspects
of metalworking.
The program is held to a total of 12 members so
there are only 3 per station. This provides a good
student to instructor ratio and creates an exciting
learning environment.
Due to the positive response, once again lunch will
be provided as well as morning refreshments.
All of this is at the bargain price of $70.00 for the
whole day.
Brentwood North generally sells out so don't
wait. Contact Bob Menard for more information.
ballandchainforge@yahoo.com,
or at the shop 207-878-2217
Rhode Island
28 February the Southern Bunch entertains the
CBG and others at South County Museum, 10:am to
3: pm. Bring items for show and tell or demo
Contact Jim Crothers (401) 783-5400
March 28 the Southern Bunch at SCM contact Jim
Crothers (401) 783-5400
New England School of Metalwork
January 23-26 Forged Tools of the Blacksmith
February 6-9
Forged Botanical Forms
February 20-23 Pattern Welded Steel
March 6-9
Open Forge for Beginners
April 17-20
Creative Joinery
See the web site for class details,
call to register 1-888-753-7502 or online at
www.newenglandschoolofmetalwork
Inquiries to dglaser@newenglandschoolofmetalwork.com
January 24-25
Intro to Blacksmithing
February 21-22 Early American door Hardware
March 14-15
Intro to Blacksmithing
March 21-22
Intro to Tool Making
April 11-12
Tool tune-up
See the web site for class details or call (802) 472-3899
www.lucianaveryblacksmith.com
Lucian@lucianaveryblacksmith.com
Winter 2009
Page 4
New England Blacksmiths
From: "obostrom" obostrom@cox.net
All,
ACBC
NEB participated in or actually was a leading partner in the Atlantic Coast
Blacksmith Conference (ACBC) in September. NEB had agreed to put up as
much as $2500 advance money to help get it going and with that we got a voice in
how it would be done. Myself and the BOD provided guidance to our ACBC representatives, Ralph Sproul and Bob Compton, and they did a wonderful job of
carrying the message and helping to guide the group overall. There were many
lessons learned. It was interesting for me to note that the huge experience that
NEB has gained by putting on two major events a year was a critical factor in
guiding the planning and toning down of some participants grandiose expectations
by interjecting some sense of reality. The conference was a smashing success and
more than 30 NEB members were able to attend. I was there and enjoyed the
show, the camaraderie, and yup, even the work when required.
Ralph and Bob did the NEB a great service by being great representatives, and NEB participants did us all
well by being a large component of those who attended and helped on site with the chores that needed doing.
There was another side to the event which was the money side. There were ultimately three groups that
equally pre-funded the event. We all ended up putting up $1500 as that was all that was needed up front. The
conference went well enough that after all costs, taxes, etc were resolved, we had our $1500 returned intact
and received another payment of $3500 profit over and above our initial grubstake. All three principle groups
elected to leave some cash in the limited liability Atlantic Coast Blacksmiths (LLC) that was formed in NY
State (as required by state law). This was to address end of the year filing costs and to maintain the LLC status
in case we want to have a similar event in the future (and I think we do). Some of our start up costs included
setting up the LLC and I see no reason to do that over again when we can economically maintain what we have
established.
So there you have it. A Great job, a Great meet, and not a bad boost for the treasury.
Hopefully, Fred can put this note in the Newsletter for those who don't follow the e-mails.
Owen Bostrom, President, NEB
15 November, 2008
ACBC NEB fall meet – it may have passed – but it’s certainly NOT being forgotten.
I’d like to thank all those who attended the Regional
Conference in Ashokan, New York in September. This was
a first time Regional conference to this area- and it was a
tremendous success due to the efforts of many NEB members. This was a first time ever event put on in lieu of the
failed ABANA conference that was supposed to happen in
New Paltz, New York (but it ended up cancelled by
ABANA). Our event offered the opportunity for blacksmiths from Maryland to Maine to get to know one another,
expand their network, see a fabulous gallery of everyone’s
work, select tools and equipment from a myriad of tailgaters
& vendors, and then check out the demonstrators, lectures,
slide shows, and mini demos that happened mid day and
evenings..
Ralph and Jim, tired but content!
Winter 2009
Page 5
New England Blacksmiths
The NEB used the Regional event as its fall conference and I counted 50 NEB members & spouses on
the registration list that made the trip. I’m sure if you talk to anyone who went – they will be saying………”Do
it again!”. Seeing as the registration for the event was 211 – the NEB was very well represented and I didn’t
hear anyone complain about the drive for what they got when they got there. Most said it exceeded their expectations………which was nice to hear.
Mark Aspery
Peter Ross
Everyone who attended the Atlantic Coast Blacksmiths Conference had the chance to learn some great basics from
Mark Asprey from California (Mark was a very popular demonstrator) and his presentations were informative,
lively, and very entertaining with his “British” sense of humor.
For those who
Ross’s Dividers
wanted to learn
the Traditional
side of smithing
from Peter Ross,
Peter demoed a
nice strap hinge
and set of dividers
during his sessions.
David
Norrie
Winter 2009
Page 6
If you were into Architectural forging you
got to watch David Norrie work on a decorative grille in one demo, a butchered and
chiseled scroll next, and finally a three
leafed vine element is his last demo.
New England Blacksmiths
Bob
Compton
In our lectures and mini demos many topics were covered from hinge jigs for strap hinge eyes, to air hammer rebuilding topics for those who have hammer issues in full time shops. Another mini demo was done
by our own Bob Compton as he presented a clever
way to forge a dragon fly from a piece of pipe and
two pieces of flat bar. Rich Waugh from St. Croix
gave a talk on his techniques for using an air gun for
doing butchering, engraving, chasing & reposse work
with a hand held gun. We planned our conference
around appealing to all levels along with a varied program, and I feel it worked out well.
The NEB made a stellar effort in supplying tools,
gear, equipment, and volunteer assistance with setup,
tear down, and during conference chores. Many thanks to David Hageman, Mark Kellogg, Steve Melady,
Bob Compton, Jim Fecteau, Bob Phillips, Susan Madasci, Owen Bostrom, Bob Menard, Richard
Spreda, and Fred Mikkelsen. These NEB members were always seen making things go smoothly. (big surprise)
Many members commented on how they liked the
opportunity to see each demonstrator, and loved
the staggered schedule. This was an idea for three
Winter 2009
Page 7
New England Blacksmiths
demonstrators to present at only two stations and it really worked out well. Demo rotations also allowed the
demonstrators to watch other demonstrators which they commented on enjoying as well.
The figures are still being worked on, (see Owen’s message on page 5) but we definitely made our seed
money back from the event and will be splitting a three way profit with the other two supporting groups – so
Bob Compton and I would like to thank the NEB members who believed in us and backed us financially to
help make this such a successful event that will more than likely happen again I have sent Fred a disc full of
pictures of the site, demonstrators, gallery, and some of the people who made this event a lot of fun. I’m sure
he’ll select some good ones to share with you.
Ralph Sproul
The crowds were kept awake!
Late into the nights!
Iron Kiss hammer arives
At left: The dinning Hall where 3 square meals appeared
each day.
Good and Plenty, meals for us all and served by the most
pleasant and hospitable staff one can imagine.
Note the heads are down and the elbows up as blacksmith
appetites are legendary.
The Editor wonders why Ralph didn’t mention the excellent
food service?
Winter 2009
Page 8
New England Blacksmiths
ACBC Gallery photos
Codington Fletcher
Susan Madaci
Every element of the craft was represented in
the Gallery organized by Susan Madasci and
volunteer helpers
Winter 2009
Page 9
New England Blacksmiths
Bill Clemens
Leigh Morrell
Winter 2009
Page 10
New England Blacksmiths
Bob Cerny’s clock that had to seen to be believed!
Judy, of the Blue Moon Press, came
with a trailer full of books and went
home with empty cartons!
Morrell Metalsmiths tailgate set up
was one of the many, plus vendors.
Jonathan Nedbor’s spot at the tailgate field.
Winter 2009
Page 11
New England Blacksmiths
COMING ATRACTIONS
NEB SPRING MEET @ BRENTWOOD, NH on May 15th to 17th, 2009
Featuring Dan Naumann of the Bighorn Forge, Kewaskum, WI
Artist’s Statement
"Forging metal has become a passion and a livelihood that
has patterned my vision in life. I have arrived at a stage
where I no longer grapple with the material. I revel in exploring the styles of the past, as well as expressing new
visions in metal. The essence of my skills flow from intense tutelage as well as the finished works of numerous
metal artists, coupled with many years of my own practice
and studies in iron and copper. Fortune has allowed me the
pleasures of forging a potpourri of styles and designs in
furniture, accessories and architecture. I derive immense
satisfaction knowing that my work resides alongside other
architectural master's works—both past and present."
Dan Naumann
Watch for your Meet package in mid April
Winter 2009
Page 12
New England Blacksmiths
Neil Mansfield and those GREAT students from Assabet have been busy demo’ing the craft & skill !!
Note the NEB Trailer
At the Fitchburg Forge-In (above)
And at
At the West Boylston 200th founding Celebration: Yesterday, was a fun filled day for all ages at the West
Boylston’s Bicentennial 200 year event. Their was so much to take in while walking around the fair grounds
ranging from native Indian drum chants, and a real tepee to visit, to hand caving of wood barrels, to Scottish
bag pipers, to face paintings, to arts and crafts for sale, to folk music bands , to an enormous bon fire at
night , and finally a main street town parade.
Assabet students once again jump at the opportunity to reach out and show the public that the age old art
of blacksmithing is still alive and kicking. Students from all grade levels ranging from seniors down to freshmen participated in a community service demonstration to the citizens of West Boylston Mass.
These kids are motivated and have a strong passion for moving hot iron. Many of the citizens of West
Boylston commented on how well the students worked together and how talented their metal work was. The
kids just combine their technical welding and sheet metal skills along side their blacksmithing skills.
The weather was perfect, the student’s metal spirits were strong, and the citizen of West Boylston was very
appreciative of Assabet Valley students putting on an exciting event in moving hot iron.
(Continued on page 14)
Winter 2009
Page 13
New England Blacksmiths
Forging with a wind chill in the very low teens ! !
Who says they don’t make them like they used to??
Assabet Student's are once again, forging hot iron creations for a New England Fall Festival
This past November, a small group of Assabet Valley students gave up their spare time to perform some
community service with a blacksmith demonstration to Red Apple's Farm Fall Festival event in Phillipston,
Massachusetts. It just happened to be the coldest fall festival that the town of Phillipston has ever experienced, as you can see by the faces of the kids the temps. were in the single digits with a wind chill factors to
contend with. However, these kids got to be working at one of warmest outside events in the entire festival. Hey the blacksmith's forge was a place to be that day ! Several small children with their parents stopped
by to tried their hand at blacksmithing as our students took the time to teach and help them. What a great
concept, for community service projects young adults teaching other young adults. In addition, many
hand crafted artists were on hand to sell their goods, as well as live farm animals, horse drawn hay rides for
the kids, and even a civil war reenactment camp. The theme for this fall festival was, traditional New England
hand crafts. Prior to this event, our students built their own coal fired forge and showcased their first public
forging talents by making tools and cooking items for the fire place. Great day for the teens, and adults alike.
These are some real hardy and passionate New England teenagers enjoying making hot iron news!
Submitted by: Mr. Mansfield Metal
Fabrication's Lead Teacher
Evan Smith created this retirement
award for a retiring teacher in the
Metal Trades Dept. At Assabet.
Winter 2009
Page 14
New England Blacksmiths
Introduction to Knife Making with Justin Mercier at John D’Abate’s
October 25th,2008
First things first! Doughnuts and coffee—then things can get
started!
I counted 20 in
attendance.
Justin began with nomenclature and terms that knife makers and designers use to describe a blade.
He explained styles and specific designs for special uses.
He went on to explain blade steels and where to obtain
them, followed by one of the best descriptions of steel
heat treatment why’s and wherefore’s I ever heard. Justin had preprinted fact sheets so you could easily follow along and add any
notes you might need to reference later.
He went on to begin forging the blade you see finished at right
(note the bone handle is for an owner who is left handed)
As he worked, he explained the do’s and don’t’s that will get you
to a well shaped blade and one that will require the minimal amount
of grinding.
With a little time left, He began the process of making some cable
Damascus. Pointing out the types of cable lending themselves to the
Process and cleaning, fluxing and starting the weld.
Time was running out so we’ll have to schedule another session devoted to laminated steel blades That is if Justin is willing!
Thanks go to our demonstrator for his well prepared demo and to John D’Abate for his gracious hospitality!
Fred Mikkelsen
Winter 2009
Page 15
New England Blacksmiths
The NEBList, e-mail group, posed a question about welding cast iron
Here’s some thoughts I’ve got on cast repairs and welding along with preheats, alloys,
and other methods. From Ralph Sproul
In case anyone wants to know more about welding cast (without fancy super alloy rods)………..the real deal
to preheat is in the carbon content………meaning how hard something will be after welding due to super intense local heats and quick cool downs due to the heat sink of said object sucking the heat from it (in a quenching manner of sorts).
Any mid to high carbon steel should be preheated prior to welding to cut down on hydrogen embrittlement
and under bead cracking in the affected weld zone.
Medium carbon steels are .5% and high carbon steels are up to 1.0% (such as the case in 52100 – bearings –
that has 1” carbon) This one percent carbon can make something very hard (and brittle if not tempered back)
With Cast steel that carbon content runs in the 1-2% range – so cast steel must ALWAYS be preheated to
weld.
With Cast iron – the carbon content is in the 2-4% range and that also must be preheated to weld for success.
This however does not apply to some rods and super alloys where they have been formulated to work in less
than desirable conditions (meaning folks who don’t or don’t know to preheat). Preheat can also help with failure rates with these rods (but when one pays $15-$80 per pound for some of these super missile rods from
“wicked good salesmen”……they expect them to perform.
Welding with a lesser alloy rod can be just as successful with pre & post heats as it’s the rate and even cool
down that is more important to things like cast steel and cast iron – as they are so brittle from such a high carbon content.
I think preheating to weld with a “too small welder” comes under the topic of working with what you’ve got –
as compared to being mandatory for proper cast welding (but non the less it’s a great point to bring up).
There are about 8 different rods for welding cast (that I know about) – and they all have parameters and guidelines to follow………and can be used in different process (cold welding mentioned below)
Another great trick to welding cast is to clamp it to a heat sink (large metal object) to hold the heat so less
stress is implied into the part during the welding process.
They even have rods for welding cast which are meant to do cold – which is another method of welding
cast………..clean & V out damaged area/crack, etc. Weld ½ to ¾ bead…………let come to totally cool to the
touch with no indication of heat by your hand what so ever……..then do the next ½-3/4 bead and allow to
cool………until your done. Going fore and aft to keep tension in the part equal is wise – and going in a bolt
pattern like shape can also be helpful with some repairs to keep tension and stress equal across the part.
This “weld to cold” welding process I mention is best used on weldment configurations where there are many
cross sections coming together at the same time – so it’s almost impossible to keep stress levels under control
– so the weld to cold to the touch is a GREAT method to achieve success in parts like that.
(Continued on page 17)
Winter 2009
Page 16
New England Blacksmiths
The first picture (at left) attached is
of a heat sink applied as a guide and
“keep hot” a broken CAST STEEL
ram from a power hammer.
The second picture (at right) is of a cast iron
piston where the damage from a broken rod
breaking a compressor piston left repairs
mandatory. This is where the weld then let
go. To do the repair totally cold is mandatory – there were way so many cross sections in the piston head, skirt, and inner hollow air passages that one could not control
all those stress direction by heating prior to
welding. This root pass took all day – but
when it was done – it was fine. The hammer
is still running – so that’s a good sign of a
successful repair.
I’m writing an article along with Jim Fecteau about the repair of his broken Beaudry power hammer spring
arms that those who like welding and attempting repairs may find interesting – or yield enough info so you
know to look for help when attempting repairs that may be
over your head.
I like Joe’s repair on the vice parts and forgot to mention it
is wise to drill a hole at the end of a crack you have ground
out for repairs - to stop further travel in cast iron. It is an
easy
task and a form of cheap insurance.
Ralph Sproul
“Pay attention,
become a Sproulie”
Winter 2009
Page 17
New England Blacksmiths
A Letter to the Editor
Hello Fred,
In the past two years I have received calls from 2 blacksmiths whom I have known for
as long as 15 years. In both cases, over time, I have encouraged them to join the New
England Blacksmiths- to no avail. Now both- using the words “in hind sight”- admit
they wish they had availed themselves of the benefits of membership rather than struggle alone to advance their craft. I have lost contact with the gentlemen, but perhaps
others, considering membership, could benefit from their lost opportunity. Please share with the readership and
anyone who is “fence sitting” about joining NEB…
About 3 weeks ago I expressed the need for a replacement spring for my 1890’s 50 lb. DuPont power hammer. You replied by sending my "quest" out to the NEBList. Well, they responded in short order, and bottom
line-I am the happy owner of a brand new 50 lb. Little Giant spring that works like a charm! So the old hat is
off to you and the gents (Leigh Morrell, Ralph Sproul and Richard Spreda) who responded. Ralph immediately went on a search and made good suggestions. Richard even volunteered to loan me one until I could find
a spring! It was Leigh’s nudge towards the Little Giant folks in Nebraska that turned up a “keeper.” Bottom
line… I have an early Christmas present and couldn’t be more pleased with the results. (This is only one of
many experiences that have made NEB member dues one of the best investments of my life).
Many thanks for your tireless efforts as editor and for passing along my ‘quest.”
Sincerely, Keith A. Leavitt
Photo copy, if you don’t want to chop up the newsletter!
NEW ENGLAND BLACKSMITHS MEMBERSHIP FORM Dues are $20.00/yr. (Canadian: $32.00)
due each January 1. Send checks to: NEB Membership, PO Box 391, Manchester, Maine 04351
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Winter 2009
Page 18
New England Blacksmiths
POWER HAMMER GUARDS by Keith Leavitt
So you still operate your trip hammer without a guard? Isn’t it time to do something about that dangerous condition? Back around the turn of the century, when the manufacture of mechanical hammers was reaching its zenith, operator safety was low on the list of priorities. Durability, simplicity, and ease of adjustment were some of the pitch
words in the early advertisement of these workhorses. Guards were rarely included as standard equipment.
I just had a “near miss” that prompts this article: At approximately 4:30 PM on November 10, 2008 I was making the
final draw on a length of stock, when KA-BOOM! There was an immense exploding sound. My immediate response
was to pull my foot off of the tread bar, as shards of spring fell down around my feet from under the guard. I shut off the
line shaft motor switch, and just stood there in a state of denial. “No way!” I was shocked but also there was a feeling
of deep relief - there was a guard between me and the ugly, potentially fatal event that just occurred in the oscillating
spring area of my power hammer.
After taking a look inside the wrap-around guard, I just packed it in for the day, leaving all parts where they landed. “I’ll
deal with this tomorrow” After turning in for the night I laid there thinking how, by the grace of God, I had listened to
the late Bud Oggier, NEB/ABANA icon, when he admonished anyone with a mechanical hammer to “Put a guard on
it!”
Twenty years ago it took me some time to figure out how to build, and where to mount, a guard for a machine that was
manufactured without one, but was also designed to position a person’s head within striking distance of a “mechanical
whirling dervish.” Listen to this taken from the early literature of the Barbour Stockwell Co. on the Dupont hammer,
p.2: “Being compact in design… it is possible for the operator to stand close to the dies and thus to handle the work to
the best advantage.” And that is what we expect to do - stand close - but without a guard I think my lights could go out
in a nanosecond - especially if a side arm or pin breaks.
The recommendation of guards, eye or safety protection of any sort is welcomed by most guys about as enthusiastically
as a plea for dental x-rays or colonoscopies. “What! – I don’t wanna hear it - I need to get paying jobs out the door!”
“Do you know how long it will take to build a rig I may never use?” Been there. I had to wait 20 years for my guard to
“kick in” i.e. protect me.
I realize I am preaching to the choir here as most are already convinced of the value of safety restraints. Still… in 72
years I have lost 4 close friends where a guard or restraints of some sort could have prevented being “taken out”: Two
were lost to auto crashes (no seat belts) - one to drowning (no life jacket) - and one to a fall in his metals shop (no loft
railing). And as a career shop teacher I have witnessed dozens of foiled accidents, thanks to safety devices.
There are two guard styles: The restraining “keep away” kind and the confining “containment” type. The restrainers
keep personnel from falling into or reaching into the churning “meat grinder.” The confiners help prevent deadly flying
missiles. A ruggedly built guard can accomplish both goals. Whatever design you chose, be sure to over-build it. Hinge
it or build it in a way that necessary lubrication to the ram/arms area will not be neglected.
Visit shops that have power hammers - talk with the owners of guards - study what is already out there. . Also, visit
blacksmithing web sites – many have photos that show hammers with guards. If you are willing to search, back issues of
the NEB News letter and The Anvils Ring also have guard photos.
. If anything I have shared here will “move you off the fence” and prompt you to start the guard building process, I will
be more than repaid for writing this article.
Safe hammering! And “Put a guard on it!”
Keith A. Leavitt
Editors Note: In the next issue Keith continues with a lengthy article on brakes for our old hammers.
Winter 2009
Page 19
New England Blacksmiths
Charlie’s Challenge
Ok Fred….here’s something for ya…a bit of a story and its outcome…………..like most of us here in this
blacksmith circle I have a passion, well, more like an obsession, for working metal…the thing is, I’ve been blessed with
the opportunity to have practiced one aspect or another in
actual employment…industrial style….shipyards, fab shops,
steel factories and power plants….and in the past few years,
I’ve discovered that I can, on occasion, in a hobbyist kind of
way, come up with pretty things….pretty things that are useful and appreciated by others….anyways, a few months back,
I got a call from a fellow in the nearby town of Preston,
CT………..he’s with the town’s historic society and they had
a renovation project which needed a metalworker….they
were looking for someone to replicate a roof cap…an ornamental finial for a Victorian (Queen Ann style) structure
….the roof had been renewed but the existing finial which
crowned the roof was in such a deteriorated condition , the
desire was to have a new finial replicated.
So I had a look at the original and came up with a set of dimensioned drawings to fabricate a replica……..
The original finial is a superb example of the sheet
metal craft, it is composed of 18 GA galvanized
steel with lead soldered seams….the spikes and
band around the sphere are sheet zinc and the topmost element, the twisted torch, is also sheet zinc…
it dates to the 1890’s……..for me, the most difficult aspect of the project would be to replicate the
so called twisted torch assembly.
I had all kinds of ideas and suggestions from comrades on how to proceed. They included such
things as “make a mold and cast it”, “carve a wood
form and hammer sheet into or over it”, “use bar
stock like a closed onion basket twist”. Well, I’m
no foundry man nor mold maker…neither am I a
woodcarver, tinknocker nor repousse artist…….mostly, I’m just stubborn , pigheaded and naïve ……(they
call us “steelheads” in the shipyards) …I went through several evolutions, trial and error like, attempting to
twist bundles of bar into a closed onion shape with no satisfactory result….the next set of trials involved wrapping bar stock around an armature which represented the geometric volume of the
twisted torch…that proved close, yet the curvature of the bars over the armature was
not consistent…too many flat spots….the final
evolution which ultimately proved successful
was to fabricate a full mandrel upon which bar
stock of half round cross section was wrapped.
Looking at the original twisted torch and breaking it down dimensionally, the task was to form
6 pieces of half round bar (1 1/8” wide x 9/16”
thk x 20” lngth) over a mandrel roughly 16
inches tall and 3 ½ inches at it’s largest diameter.
(Continued on page 21)
Winter 2009
Page 20
New England Blacksmiths
The mandrel starts off as a tube..3 ½ OD x .120” wall x 18”……in developing the method for fabricating the
mandrel I made a scaled prototype…..forging down 1 ½” OD tube with spring fuller to accomplish the elliptical volume….3 ½” OD was far too formidable a distance to fuller
down the full tube by hand hammering….so to make it easier on
me, I removed excess
metal from the circumference of the tube with
a plasma torch…the layout for torch cutting begins with a full size
drawing (elevation
view) of the 3D mandrel
I printed out 3 copies
(full size) and affixed
them (evenly spaced)
around the circumference of the tube, transferred the lines to the
tube and cut the excess
out in three stages …
each stage leaving
enough of the tube intact
so that the round volume
was maintained while
forging down each section from top to bottom…as each stage was
forged down to a satisfactory volume the resultant seams were arc
welded together, which
provided the structural
integrity to maintain a
symmetric volume for
the subsequent cuts and
forging.
The completed mandrel
was affixed to a vertical
stake and the half round
bars were tack welded to
the apex ….using a rosebud torch, bending forks
and perseverance, each
bar was subsequently
wrapped around the mandrel...tack welding as it progressed
The resultant assembly of bars over mandrel was then arc welded
at the intersecting edges. Completion of the torch assembly was
accomplished via abrasive disc and pointed stone grinding to blend out the welds and define the lines of the
torch.
(Continued on page 22)
Winter 2009
Page 21
New England Blacksmiths
left: compare
Charlie’s
replica
with the
original
Right: Installation
day and
note the
sky hook!
Left: New Crown on the Queen Ann Victorian
The rest of it was incidental forge work and a fair amount of
fabrication type stuff….the completed assembly looking like
this :……Now I recognize that this is a long winded story
here, and too, I expect a massive file size document…….feel
free to edit and use whatever you can,,,,…..Charlie Sedell
The Editor comments:
Charlie,
Thanks so much for sharing this with all of us and writing
this great story of perseverance and innovation. It was just
too good to edit or reduce in any way, thanks again.
Fred Mikkelsen
Winter 2009
Page 22
New England Blacksmiths
The Ashokan Bench
While it is defiantly NOT a blacksmithing project,
Even a blacksmith can do it!
The benches at the Ashokan pavilion during the Atlantic Coast Blacksmith Conference, were a most
comfortable spot to park ones backside.
They appeared to have been constructed of “reclaimed” or used lumber. You can do the same, as
long as you assure splinters and protruding nails
have been eliminated!
The bench pictured at left is made of used pieces of
2” x 12” shelving given to me by a neighbor with the
suggestion I burn it in my wood stoves!
It was much too good for that and I stored it waiting
for another use to pop up and at ACBC, it did!
I traced the angles from the Ashokan bench and soon
after the ACBC, built a “prototype”. Then went on to build several for family and for the guy who had given me
the 2” x 12” stock and he & his wife were delighted.
These drawings make this a “Wordless Workshop” kind of exercise and I’m sure you can make adjustments for
2” x 8” or 2” x 10” stock. (I think 2” x 6” would be too narrow) The heart cut out was my wife’s idea and does
give it a little class. (If it wasn’t for her, I’d be classless as well as clueless)
You’ll need:
2- 8’- 2 x 8, 10 or 12’s
6– 3-1/2 x 1/4” galv. carriage bolts, nuts &
washers
16– 3” fine tread screws (coated or SS if left out
in the weather)
The angles can be laid out with a carpenter’s
square or you can make yourself a template using a piece of card board.
Remember that the “seat” will be shorter than the
“back” by twice the thickness of the “2 by” lumber.
Assemble the “legs” aligning their bottoms to a
straight edge, clamp and drill 3 holes for the
bolts. DON’T FORGET RIGHT & LEFT
Attach the back with 2 upper screws,- square up by measuring diagonally from top of back to bottom of the
opposite leg. (pre-drill for screws, guaranties tight connections)
Then finish with the other 4 screws. Then add the seat, leaving it with a slight (1/2”) overhang of the legs.
Run over the edges with a fine rasp and then overall with a sanding block or palm sander.
SIT DOWN, RELAX
Fred Mikkelsen
Winter 2009
Page 23
New England Blacksmiths
Arizona Artist Blacksmiths
Winter 2009
Page 24
New England Blacksmiths
This chart was supposed to be in the last issue! FWM
Winter 2009
Page 25
New England Blacksmiths
Jim Fecteau’s Big Adventure
Frank Lloyd Wright's “River-house”, inspired the design of this new construction project. It sets on ledge overlooking the Mad River and was originally the site of a hydro power dam. That dam was destroyed during the
flood of 1927.
I got called in on this job to build fireplace
screen doors that slide into pockets on ether side
of the stone work done by the mason. One job
led to the next the first of witch was the 150' of
railing to be done outside.
This is the design Que. that started the railing concept.
The shot with Lucian in it is the old dam (not “damn
old Lucian”) abutment. The penstock and sluice way
are directly below where he is. The drop to the river
there is 50 feet.
The solar array units heat water that is stored in a
huge holding tank. The house has 16" of insulation in
the walls and 36 in the roof. It has geothermal heat/
cool as well. There is 60' X100' array
of photovoltaic panels out in the field up stream of
the house.
.
I was also asked to make lighting fixtures that fit into precast pockets inside of stone pillars (8 total)
They will be done with Mica lenses and be lit with LED lighting. In addition, I’ll be forging ladders that will
lead up onto two lofts in the main house. They have asked me to build a mirror that will swing into place
and swivel to a magnified mirror and cooking andirons for the fireplace.
(Continued on page 27)
Winter 2009
Page 26
New England Blacksmiths
The solar array frame, in the foreground of the previous picture, was an add on that was way over the top for
me to handle by myself. I got Ralph Sproul to help me there. Well the solar array guy held me up 4 weeks
and at this time of year that is NOT an option SO I wound up falling behind on my before Thanksgiving
deadline.
So I had to call in
for reinforcements, Ralph, a guy by
the named Matt and Lucian Avery
(Lucian called and said he could
help out of the kindness of his
heart) We knocked out a mess of
work the Thursday the week before
Thanksgiving and it was all painted
by Friday. I set things up on Saturday and Sunday and I think it was
Monday that we did the install.
Jim texturing components
on the Beaudry
A crazy time to be sure! I’m so glad we
have such great Smiths up in this neck
of the woods.
I think this is a great story as there are a
lot of pooling of resources that needs to be
told....
Headed for the Paint
Shop
My guess is this article would help a smith say "yes" to a job that seemed way over their heads.
Jim Fecteau
Winter 2009
Page 27
New England Blacksmiths
ABANA
New & Renewal Memberships
Name : __________________________________________Business Name optional__________________
Address : ____________________________________________________________________________
City : _______________________________________ State ; ________________ ZIP : _____________
Phone : _________________ E-mail : ________________________________
Membership Type : ____New
Renewal : _____
Regular (US) $55 one year * Senior $50 one year * Full Time Student $ 45 one year
ABANA, 15754 Widewater Drive, Dumfries, VA 22025-1212 (703) 680-1632 or www.ABANA.org
Why would I want to join ABANA? ?
Well 2 great publications sent to your door 4 times a year,
The Anvil’s Ring and The Hammer’s Blow.
ABANA Members Grainger Program (10% to 50% off products you want and they sell)
And now something we all need:
ABANA TransChoice Plan (Comprehensive Health Plan, a Prescription Drug Plan, Dental Plan and Vision Plan
Enrollment has been extended to January 31st, 2009
New ABANA members may apply for the coverage in the first 60 days following the initial
membership in ABANA.
It is well worth taking a look at what is being offered through membership in ABANA
Winter 2009
Page 28
New England Blacksmiths
NEB Stuff by Mail
Get T-shirts, sweatshirts and other good stuff featuring our great logo
By sending a check or money order made out to new England blacksmiths
Mail to:
Neb Stuff c/o Dondi LaRue
P.O. Box 58
Ashby, MA 01431-0058
Please remember to tell us what you want, how many and what size. We will try to honor color selection, but
color depends on stock at hand. Tell us your second and third color choices. Total your order and remember to
add postage. Payment to: New England Blacksmiths. Please include your mailing address and phone number.
Before 9:00pm, you can call Dondi at (978) 386-7101 to see if there are any “deals” to be had.
Sweatshirts
T-shirts
Adult 100% cotton . . . . . . . . . . . . .$10.00
“ “
“
long sleeve . . $15.00
Kids. . . . . . . . . . . . . . . . . . . . . . . . $ 6.00
Postage for the average order $4.00
Adult crew neck . . . . . . . . . . . . . . $18.00
Adult hooded . . . . . . . . . . . $25.00
Others
Patch, NEB logo . . . . . . . . . . . . . . $ 3.00
NEB caps . . . . . . . . . . . . . . . . . . . $12.00
Bumper Stickers and Hat pins now, too!
What other items would you like to see offered in our NEB “store”? Call Dondi or your
state representative with your suggestions!
NEB Tail Gate Listings
We’ve re-stocking our excellent swage blocks
and cone mandrills. Quality tools sold at cost to
you as a benefit of membership.
Current prices are:
Swage Block $135 + $25 shipping & Handling
Cone Mandrill (5 in stock) $ 45 + $12 shipping
& Handling.
Coal - always available - current price remains at
$18.00 per 100# loose. Pick up in Colrain, MA
New items in:
Set of tire rolls, 5T punch press, several very nice anvils from 83# - 165#, couple of coal forges ready to
work, and leg vises from 3.5" - 6", an excellent Diacro
#2 bender, a #10 Edwards floor shear, Niagara double
end floor shear/punch. As well as other new and used
equipment.
Call for directions, current availability, and pricing at
413-624-1200 Leigh Morrell
Bob Compton has developed plans for a gas saver
torch stand and has them for sale at a reasonable price.
Call Bob at (413) 625-9599
Just in case you missed the
fire pot story on the bottom
of page 3, here is the mentioned tuyere.
For all our items contact :
Bob Menard (207) 878-2217
<ballandchainforge@yahoo.com>
Winter 2009
Page 29
New England Blacksmiths
New England Blacksmiths
Fred Mikkelsen, - Editor
23 Waterman Dr.
North Scituate, RI 02857-2036
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