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Ribbon burner forge build
December 14, 2010
4:14 am
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J Wilson
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I was surprized to learn that a potter's kiln upper limit is around 2300 F.
A quick check of the internet provided the following:

Max. temp rating 2300 F
Durablanket
Kaowool Blanket
Kaowool RT Blanket

Max. temp rating 2400 F
Cerablanket
Inswool HP Blanket

Max. temp rating 2550 F
DuraBlanket Hot Face

Max. temp rating 2600 F
Cerachem Blanket
Cerachrome Blanket

Max. temp rating 2700 F
Inswool HTZ Blanket

Max. temp rating 2900 F
Maftec Blanket

Max. temp rating 2912 F
Saffil Blanket

This is just a partial list! There is more out there. Some are costly, some are not suitable for our purposes. The research continues....

My son is the Blacksmith

December 17, 2010
1:54 am
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JimB
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Grant;5303 wrote: Boy, there sure dose not seem to be as much choice as there used to be. I know the 3200 stuff was more, but only like 25% or so. (Why, back in my day...........) All the more reason to use castable.

I didn't know people used castable refractory in gas forges. I've thought about using a castable lined with ITC-100, but wasn't sure if it'd take 3 hours to warm up :p

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December 17, 2010
2:05 am
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Ries
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I have been running gas forges that are castable for a good ten years now.
Mine is a Phillip Baldwin design, solid castable, cast between two sizes of sonotube, for about a 2" wall thickness. Burner opening is cast in.
Ends are flat circles, with oval openings, cast separately, then clamped on with 4 pieces of threaded rod. Works real good.
I do wrap the outside with maybe 1" ordinary kaowool, then wrap that in SS expanded metal, so the kaowool is on the outside, and never gets worn or burned.
These castable bodies last 6 or 8 years before replacement, use a sack or so of the pryor giggey medium temp stuff- I think its the Econocast, something like the 3200. I have a bag somewhere on a top shelf, I should look and see what it is.

http://pryorgiggey.thomasnet.c.....t-castable?

Anyway, solid castable is not that hard to do, and, once you make the molds, you can make as many as you want.

December 24, 2010
4:13 am
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Larry L
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So I did a castable liner in this sucker, which was a bit of a chore because it does not lend it self well to pouring... so my solution was to carve a Styrofoam liner to pour too, which I then dug out after it set...

Here is the deal and the result...

I used mizzue with some inconel wire in spots to support where it free hangs... and I mixed in a pound or so of fine stainless wires for "rebar"

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Whatever you are, be a good one.
Abraham Lincoln

December 24, 2010
4:55 am
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JimB
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That's awesome Larry! Should hold up pretty well.

I like how you left the opening to heat over-sized pieces.

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December 24, 2010
5:55 pm
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has anyone tried replicating the square box design. like manufactured forges the farriers use?
they always seem to be more evenly heated than the cylindrical ones.
but then I still laugh that coke forges are not worth discussing for smiths.
LOL bit sad really.
happy burners

December 24, 2010
6:22 pm
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Larry L
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Actually Jack I am interested in your posts on side draft coke forges, I have only forged in one once and found it quite challenging to keep the fire to my liking.. Im sure its like anything else, I can walk up to my welder and in a few seconds without looking at any dials or readouts and tell you if its too hot, not enough wire or what ever to get a perfect weld.... I have run thousands of pounds of wire though that machine, I know it inside and out.... Is no different with a forge, when you use it daily it becomes second nature, but because its not practical for me to use a coke forge daily when I do its a struggle... I have 5 forges in my shop for various things and dont even remember when the last time I forged in coke or coal was, but I do have 200lbs of coke on hand for when the next need arises...

Whatever you are, be a good one.
Abraham Lincoln

May 3, 2012
2:39 pm
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ironstein
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Hey Larry,
Hows that cast forge holding up? How's the fuel consumption? I have been considering either buying a big Johnson forge or building a ribbon burner forge, just curious how either of these work for large irregular pieces?

February 2, 2013
8:57 am
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ethan_hardwick
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Bill Cottrell;3525 wrote: I really like the ribbon burner I made Larry. Boy it gets that forge hot quick too. It has been up to 2000 degrees and still climbing when I shut it down. I had to take the big blower off and put one of the little ones like Grant has and I'm a lot happier with it now. I can actually open the gate on the little blower about a third open. I put doors on mine that ran in a track to raise up and down -- cut them back off too - they would not work when everything got hot (that was when it was at 2000). So I made some castable doors for mine that hinge from the sides and they are working well. I left a 2" opening on the bottom of the doors for gas to escape from. Nice looking job - you will like that burner!

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