anvilfire iForge Demo Candle Holder

Bill-Epps : `02:46:10`	Sorry I don't have a picture of the finished piece. Went to buy a digital camera, but ended up buying a Tig Welder instead. This candle holder involves scrolls, leaves, collars and a penny weld.
Bill-Epps : `02:46:32`
Bill-Epps : `02:47:17`	To start I use 3 pieces of either 5/16" or 3/8". 2 pieces are 18" long and 1 is 16" long.
Bill-Epps : `02:47:24`
Bill-Epps : `02:48:27`	using sq. stock, I point two sides 90 deg. apart on the two long pieces. This is where I am going to make the leaf.
Bill-Epps : `02:49:51`
Bill-Epps : `02:51:05`	After you make the short point, slide it over the edge of the anvil and set it down on two sides and draw out the stem.
Bill-Epps : `02:51:17`
Bill-Epps : `02:53:14`	When you get to this point, you flatten the end down and spread it out to make the leaf. I used a raised vein leaf because it is faster, but a folded leaf or whatever like of leaf you like will work just as well. At the next step, we have to start thinking "a left and a right".
Bill-Epps : `02:53:23`
Bill-Epps : `02:55:07`	Now we have our leaf. When doing a piece like this, I work two pieces of iron at a time. It seems easier for me to keep them uniform by working 2 at a time rather than making 1 and trying to make the second match it. This disk is about 3" with a 3/16" hole drilled in center.
Bill-Epps : `02:55:20`
Bill-Epps : `02:56:14`	Ok, we are out of sinc here. The short bar, we have to pull a spike on. Let's see if in next picture.
Bill-Epps : `02:56:25`
Bill-Epps : `02:56:45`
Bill-Epps : `02:57:23`	Let's go back. Wasn't able to preview before hand.
Bill-Epps : `02:57:33`
Bill-Epps : `02:59:32`	Using the short piece of stock, and the corner of your anvil and the edge of your hammer face, you start drawing the spike out, leaving a shoulder. This comes out about 1" long and down to about 3/16" square.I'm going to bring all the pictures up and see if I can figure out order on them. Sorry for delay.
Bill-Epps : `03:00:12`
Bill-Epps : `03:00:49`	Just figured out the problem. I forgot to send all the pictures to Kiwi. Still in Sketch book.
Bill-Epps : `03:01:45`	Since I have messed this up royally. I will just explain what is to be done on the steps where pictures aren't available.
kiwi : `03:02:58`	Bill, are we missing a picture?
Bill-Epps : `03:03:15`	After you get the spike drawn up which is about 1" long,. use a monkey tool to square up the edge or the step at the base of the spike. Take our disk and cup it slightly. Drive it down on the spike w/the monkey tool. This is done hot.
Bill-Epps : `03:03:37`	Yes, Kiwi, missing 2 pages of pictures. Sorry I goofed.:)
Bill-Epps : `03:04:23`	While it is still hot, sprinkle with flux. (borax).
Bill-Epps : `03:06:48`	Using a short piece of copper wire, (12 ga. about 1/2" to 3/4" long). This is going to make our penny weld. A penny weld is just copper brazing in a forge. Stick the piece back in fore and heat it til copper runs. The copper will stick wherever the flux is, so use the flux sparingly. It doesn't take much copper at all. Once the copper is melted and run, gently lift out of fire hold still til copper becomes solid.
Shannon : `03:07:57`	Is this to keep the spike standing in the cup?
Bill-Epps : `03:08:04`	This the way of joining two pieces of metal together when you are not able to make a forge weld. Now we have the disk mounted on the end of shaft. We flatten out the other ends of all three rods, and make our scrolls.
Bill-Epps : `03:08:22`	Yes it is.
Bill-Epps : `03:08:32`
Bill-Epps : `03:09:48`	This shows monkey tool setting disk down on spike getting ready for what I have just explained.
Bill-Epps : `03:10:01`
Bill-Epps : `03:11:35`	We bend each leaf, one way, one the other (right & left) so the three can be joined together. Now we are ready to collar, NOT the way I have shown here. That is where collars are going to go.
Bill-Epps : `03:11:46`
Bill-Epps : `03:15:44`	I clamp these in place, some would tack weld together then grind the weld flat. Seems like unnecessary trouble to me. We will cut collar straps using 1/8" X 1/2". There were 3 pieces of 5/16" that we collar together. To determine the length of collar stock, take distance all the way around which is 15/16 twice plus 5/16 twice. which is 2 1/2" plus two times the material thickness which = 1/4"
Bill-Epps : `03:16:47`	I make a saddle that is the width of my work plus the collar which in this case is 1 3/16". This saddle is piece of flat bar with 2 block welded on it w/1 3/16" gap in it.
Bill-Epps : `03:17:08`
Bill-Epps : `03:17:33`
Bill-Epps : `03:19:20`	I heat the collar stock up and form it to a "U" shape in the saddle. Heat it again, set the U in the saddle, the piece inside the U and fold the tails over til they meet. Do this for bottom collar then the top collar. I heat the base and turn the legs on the two outside til they are 120 deg. apart.
Bill-Epps : `03:19:52`
Bill-Epps : `03:20:44`	Heat the top leaves up and shape them to suit where they are astetically pleasing.
Bill-Epps : `03:21:44`	I have to apologize to every one for not having my ducks in a row. I will send Kiwi the rest of the drawings, and he can post them on the IForge page, and they will make more sense. Also I should have a picture of the finished piece by then.
Bill-Epps : `03:22:00`	This is a very pretty candle holder. Do you have any questions?
Allen : `03:22:54`	What would the selling price be for one of these ?
amarda : `03:23:07`	This is the first time I've heard of brazing on a forge. It's very exciting, can you say more about it?
Gordon : `03:23:18`	Length of time in the making and approximate selling price.
Jim-C : `03:23:36`	Penny weld -- how did you keep the copper from running off the disk?
Bill-Epps : `03:25:06`	Copper will melt at about 1500 - 1600 deg. It will stick to area that has the flux on it. Just as soon as the copper runs, you take it out of the heat (very carefully) It will immediately start cooling and become solid.
Bill-Epps : `03:25:42`	This is the way that toe grabs were put on steel race plates for race horses before aluminum race plates became so popular.
amarda : `03:26:05`	do you use borax flux?
kent : `03:26:07`	what kind of flux for copper?
Bill-Epps : `03:26:44`	This process can be done in both coal and gas forges. I use plain old 20 mule team borax.
Bill-Epps : `03:27:40`	If doing this in your gas forge, careful not to use too much copper, and let it run off or it will blow a hole in your liner. Any place hot copper touches hot refractory material, you will end up with a divot. That is why I prefer to do this in a coal fire.
Travis : `03:27:45`	Can yu do same with brass brazing rod as with copper?
Tom-Stovall : `03:28:13`	Copper brazing a missed weld in a bar shoe has saved many a farrier form having to forge another shoe.
Bill-Epps : `03:28:18`	yes you can brass is a little sloppier.
Paw-Paw : `03:28:22`	Bill, or Guru. How about a short explantion of what flux is/does, and how it works. Might help folks to see why plain old borax works as well as it does. Travis, Yes. Use the flux coated kind. That's what I use.
amarda : `03:29:48`	It seems you used quite a few special tools, such as the saddle, and, how did you make a shoulder on the spike and drive the disk onto it? Was there a special tool for that?
Bill-Epps : `03:31:00`	The Flux covers the metal and seals the air from touching the steel. When steel is at a forging heat and is exposed to air, it will oxodize. The flux seals the metal from air and keeps oxodization from happening.
Paw-Paw : `03:31:43`	Amarda, Bill used a "monkey tool" to make the shoulder and drive the disk on. Is basically a piece of heavy stock with a correctly sized hole drilled in one end and a small relief hole drilled at 90 degrees. Email me, and I'll send you a picture of one.
Paw-Paw : `03:32:48`	I made a set of monkey tools out of 1 1/4" hex stock. from 1/8 inch to 3/4 inch.
Gordon : `03:33:30`	Bill, what is the approximate selling price?
Bill-Epps : `03:33:43`	My monkey tool is a piece of 5/8" bar with a 1/4" hole that I squared up on the end to accommodate the 3/16" square spike. I make monkey tools to suit the job I am doing.
Bill-Epps : `03:34:48`	I can make 10 of these in a day. They should bring about $60 to $80 depending on where you live, and what your market will bear.
J-J : `03:34:50`	Bill, don't think we really missed much. Forming leg on spike piece is same as other 2 legs.
Paw-Paw : `03:35:35`	Bill, is that 10 with hammer and anvil or with a power hammer?
Bill-Epps : `03:36:20`	I use power hammers, and jigs, Naturally (and I tack weld the dish on):)
Tom-Stovall : `03:36:33`	Paw Paw, that's an unfair question. Bill'll probably take the Fifth.
Paw-Paw : `03:37:14`	Seems to me that if you have the disk hot and the hole undersized, monkey it on, and it should stay in place without the penny weld, or the tack weld.
J-J : `03:38:02`	when bumped jim, they tend to ride up the smooth surface of the spike.
Bill-Epps : `03:38:28`	It will sometimes, but it may not stay in place, so rather be sure.