Forging a Ball

Demonstration by Bill Epps
Bill Epps Blacksmith Shoppe

September 20, 2000

 
BILL
EPPS
This is something I learned from Bob Patrick 2 weeks ago at the NTBA Hammerfest.
BILL
EPPS
I have about 3 more demos in mind, utilizing this technique. Tonight we are gonna make a Forge welded Faceted Ball on the end of a piece of 1/2" round.

Figure 01

Figure 02

Figure 03
BILL
EPPS
We start out w/2 pieces of 1/2" round. One we an eye on the end of which we will make
into a circle.

Figure 04

Figure 04

Figure 06
BILL
EPPS
You take the second piece of 1/2" rnd. and insert it into the circle and finish closing the other piece on the face and the step of your anvil. Then I use a hot cutter to cut off the excess of the handle part.

Figure 07
Cut off the excess part of the ring, not the "handle".

Now we heat it up and the ring about 1/2" back from the end of the bar and flux. (On this piece I used "E-Z weld").

Figure 08

Figure 09
BILL
EPPS
We bring it up to a welding heat, and weld the ring. (This works best when done on the step of the anvil or in a 1/2" Bottom Swedge if you have one.)

Figure 10
Keep the piece at or near a welding heat, and hammer the end back into the ring.

Figure 11

Figure 12
BILL
EPPS
I bring it back up to a welding heat and work the end back into the ring, and the ring we work into a cube. Remember, keep it at or near a welding heat at all times.

Figure 13

Figure 14
BILL
EPPS
If you have it welded correctly, you will have a solid mass in the shape of a cube. Now we want to start knocking the corners down to make the facets and you should end up w/14 surfaces or facets on the end of a 1/2" rod. Which will look like the pictures below.

Figure 15

Figure 16
BILL
EPPS
I have seen this used on andirons, fireplace tools, finnels, fences, door knockers and a lot of other different applications. Any questions???
Bobby
Bill what size will you end up with?
BILL
EPPS
You will end up w/ about 1" and 1/4" ball or faceted cube. It really works good.
TAPLEY
Bill, Why are you using EZ-weld rather than borax?
BILL
EPPS
Tapley, I used E-Z weld on this rather than borax. E-Z weld seems to hold better at a lower temperature for me than Borax.
R-B
When forming the cube you said to keep near welding heat how much color can you lose before you need to heat again?
BILL
EPPS
If you get any muddy look at all in your metal, bring it up back to a clear heat, the same color as your fire.
JOCK-D
This is a good practice forge weld. It one of the few that I ever get right every time.
AZ-DOUG
Seems like there is a lot of welding going on here. First the ring and then while the end is hammered back and the cube is made?
BILL
EPPS
I plan to do another demo of taking this welded up ball and making it into a flower on the end of a stem. You have to be able to make this ball first.
TAPLEY
This sure looks easier than using big diameter rod and upsetting and then drawing it out:-)
BILL
EPPS
Jock, this is a fun Welding project isn't it??
JOCK-D
Yes, it is! (fun)

I forge weld square collars onto fireplace tool handles use a similar method.


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