Forging your own tools offers a unique satisfaction. Among the many tools a blacksmith can create, box jaw tongs stand out as particularly useful. These tongs, with their specialized jaws, are designed to securely grip square or rectangular stock, making them indispensable for various forging operations. This guide will walk you through the process of forging your own box jaw tongs, step-by-step, from selecting materials to the final finishing touches.
Understanding Box Jaw Tongs and Their Importance
Box jaw tongs are designed with jaws that form a box-like shape, allowing them to grip square or rectangular workpieces firmly. This secure grip is essential when manipulating hot metal during forging, preventing slippage and ensuring accurate control. Different sizes and configurations of box jaw tongs exist, each suited for specific stock sizes. Having a well-made set of box jaw tongs is not just convenient; it is often crucial for the safe and efficient completion of many blacksmithing tasks.
Why choose box jaw tongs over other types? The answer lies in their superior grip. Unlike flat tongs or V-bit tongs, box jaw tongs cradle the workpiece, preventing it from twisting or slipping out of the jaws. This added security is particularly beneficial when working with heavy or awkwardly shaped pieces of metal.
Materials and Tools Required
Before you begin forging, you’ll need to gather the necessary materials and tools. This is a crucial step, as having the right equipment will significantly impact the quality and safety of your work.
The primary material for forging box jaw tongs is typically mild steel. Specifically, 1045 or similar medium carbon steel is a good choice for the reins (handles), while a lower carbon steel like A36 can be used for the jaws.
Essential tools for this project include:
- A forge capable of reaching forging temperatures.
- An anvil, preferably one with a sturdy face.
- A hammer, typically a 2-3 pound hammer will suffice.
- A rounding hammer or ball peen hammer for shaping.
- A hardy tool, such as a hot cut hardy.
- Punches and drifts of various sizes.
- A vise for bending and holding the metal.
- Tongs for handling the hot metal.
- Quenching bucket filled with water.
- Safety glasses and appropriate protective gear.
Having a dedicated area for your forge is also crucial for safety. Make sure that the area is well ventilated and free of flammable materials.
Forging the Reins (Handles)
The reins of the tongs provide the leverage and control you need to manipulate the workpiece. Forging them correctly is essential for comfortable and efficient use.
Start by cutting two pieces of 1045 steel to the desired length. The length will depend on the size of your hands and the intended use of the tongs, but typically 12-18 inches is a good starting point. Heat one end of each piece of steel in the forge until it reaches a bright orange color.
Using your hammer and anvil, taper the heated end of each rein. This taper will eventually become the hinge point of the tongs. Gradually draw out the metal, rotating the piece frequently to ensure a uniform taper. Aim for a smooth, gradual taper that is approximately 2-3 inches long.
After tapering, bend the tapered ends of the reins to form eyes or loops. These loops will be joined together to create the hinge. The size of the loops should be large enough to accommodate a rivet or bolt. Heat the tapered end of each rein again, and using a rounding hammer or the edge of your anvil, carefully bend the metal to form a closed loop. Ensure that the loops are aligned and symmetrical.
Punch a hole through the center of each loop. The size of the hole should match the diameter of the rivet or bolt you intend to use for the hinge. Use a punch that is slightly smaller than the desired hole size, and then use a drift to enlarge and refine the hole. Ensure that the holes are perfectly aligned on both reins.
Forging the Jaws
The jaws are the most critical part of the tongs, as they are responsible for gripping the workpiece. Careful attention to detail is essential when forging the jaws.
Cut two pieces of A36 steel to the desired length. The length will depend on the size of the box jaws you want to create, but typically 4-6 inches is a good starting point. Heat one end of each piece of steel in the forge until it reaches a bright orange color.
Using your hammer and anvil, upset the heated end of each piece of steel. Upsetting involves thickening the metal by hammering it on end. This will provide the necessary material to form the box jaws. Heat the end of the steel and strike it squarely on the anvil, ensuring that the metal thickens evenly.
Shape the upset end of each piece of steel to form the box jaw. This can be done using a combination of hammering and bending. Use the edge of your anvil or a rounding hammer to create the desired shape. Aim for a rectangular box shape that is slightly larger than the size of the stock you intend to grip. Ensure that the jaws are symmetrical and that the inner surfaces are relatively flat and parallel.
Once the jaws are shaped, create a transition from the box jaw to the rein. This transition should be gradual and smooth, providing a strong and comfortable connection. Heat the metal near the base of the jaw and use your hammer to shape the transition. Avoid sharp corners or abrupt changes in thickness, as these can create weak points.
Bend the jaws inward slightly to provide a secure grip on the workpiece. Heat the jaws and use your vise or a bending fork to carefully bend the metal. The amount of bend will depend on the size of the jaws and the intended use of the tongs. Experiment with different amounts of bend to find the optimal grip.
Assembling the Tongs
With the reins and jaws forged, the next step is to assemble the tongs. This involves joining the reins and jaws together using rivets or bolts.
Align the loops on the reins and insert a rivet or bolt through the holes. If using a rivet, ensure that it is long enough to pass through both loops and leave enough material to form a head on each end. If using a bolt, use a lock nut to prevent it from loosening during use.
If using a rivet, peen the ends of the rivet to form a head on each side. This can be done using a ball peen hammer. Ensure that the rivet heads are symmetrical and that they securely hold the reins together. Avoid over-peening the rivet, as this can cause it to crack or break.
Attach the jaws to the reins using rivets or bolts. The jaws should be positioned so that they align properly and provide a secure grip on the workpiece. Heat the end of the rein that will connect to the jaw and shape it to fit the jaw. Use rivets or bolts to securely attach the jaws to the reins. Ensure that the jaws are aligned and that they move smoothly.
Finishing and Refining
Once the tongs are assembled, the final step is to finish and refine them. This involves cleaning up any rough edges, smoothing the surfaces, and ensuring that the tongs operate smoothly.
Remove any scale or oxidation from the tongs using a wire brush or abrasive pad. This will improve the appearance of the tongs and prevent them from rusting. Pay particular attention to the jaws, as any roughness on the gripping surfaces can affect their performance.
Adjust the tension of the hinge. The tongs should open and close smoothly without being too loose or too tight. If the hinge is too tight, use a hammer and punch to loosen the rivet or bolt. If the hinge is too loose, tighten the rivet or bolt.
Test the tongs by gripping a piece of square or rectangular stock. Ensure that the jaws provide a secure grip and that the tongs are comfortable to use. Make any necessary adjustments to the jaws or reins to improve their performance.
Consider applying a protective coating to the tongs to prevent rust. This can be done using oil, wax, or a commercial rust preventative. Apply the coating evenly and allow it to dry completely before using the tongs.
Safety Considerations
Forging metal involves working with high temperatures and sharp tools. It is essential to take appropriate safety precautions to prevent injuries.
Always wear safety glasses to protect your eyes from flying sparks and debris. Wear appropriate protective clothing, including gloves, an apron, and sturdy shoes. Use tongs to handle hot metal and avoid touching it directly with your hands. Keep your work area clean and free of clutter. Have a fire extinguisher nearby in case of emergencies. Work in a well-ventilated area to avoid breathing in harmful fumes.
By following these safety precautions, you can minimize the risk of injury and enjoy the process of forging your own box jaw tongs.
Maintenance and Care
Like any tool, box jaw tongs require regular maintenance and care to ensure their longevity and performance.
Regularly clean the tongs to remove scale, rust, and other debris. Use a wire brush or abrasive pad to clean the surfaces, paying particular attention to the jaws. Lubricate the hinge with oil or grease to keep it moving smoothly. Check the rivets or bolts regularly to ensure that they are tight. Replace any worn or damaged parts as needed. Store the tongs in a dry place to prevent rust.
By following these simple maintenance tips, you can keep your box jaw tongs in good condition for many years to come.
What specific type of steel is best for forging box jaw tongs?
The best steel for forging box jaw tongs is typically a medium carbon steel, such as 1045 or 4140 steel. These steels offer a good balance of hardness, toughness, and weldability, essential for tools that will be subjected to high stress and heat. Using mild steel is not recommended, as it may not hold up well under repeated use and high temperatures.
1045 steel is generally more readily available and easier to work with for beginners. 4140 steel offers increased strength and wear resistance, making it a better choice for professional use or when working with heavier materials. Consider the intended use and experience level when selecting the steel for your box jaw tongs.
What are the essential tools needed to forge box jaw tongs?
To successfully forge box jaw tongs, you’ll need a well-equipped blacksmithing setup. This includes a forge capable of reaching forging temperatures (around 2200°F or 1200°C), an anvil to shape the hot steel, and a variety of hammers, such as a rounding hammer, a cross peen hammer, and potentially a flatter.
Other essential tools include tongs for manipulating the hot steel, a vise for holding the workpiece during shaping, a hardy tool such as a hot cut hardy for cutting the steel, and quenching fluids (water or oil) for heat treating. Safety equipment like eye protection, gloves, and a leather apron are also crucial for protecting yourself during the forging process.
How do you prevent scale from forming excessively during forging?
Excessive scale formation during forging can be minimized through careful temperature management and flux application. Maintaining a slightly reducing atmosphere in your forge, meaning slightly less oxygen than a perfectly balanced burn, helps to slow down the oxidation process that creates scale. Avoid overheating the steel, as higher temperatures dramatically increase scale formation.
Applying flux, such as borax, to the hot steel during forging also helps to prevent scale buildup. The flux reacts with the scale, forming a glassy coating that protects the underlying metal from further oxidation. Regularly cleaning the anvil and hammer faces also prevents scale from being hammered into the workpiece, which can create surface defects.
What is the purpose of the “boss” or “rivet boss” on the tongs?
The boss, or rivet boss, on the tongs is a critical feature that provides the necessary leverage and clearance for the tongs to function smoothly. This thickened area around the pivot point creates space for the rivet or bolt that joins the two halves of the tongs, allowing them to open and close freely without binding.
The size and shape of the boss are crucial for proper tong function. A boss that is too small won’t provide enough clearance, causing the tongs to bind. A boss that is too large can make the tongs unwieldy and difficult to control. Careful forging and shaping of the boss ensures that the tongs operate effectively and efficiently.
How do you heat treat the box jaw tongs after forging?
After forging the box jaw tongs, heat treating is essential to achieve the desired hardness and toughness. Begin by normalizing the steel, heating it evenly to a temperature slightly above its critical point (typically around 1500-1600°F for medium carbon steel) and then allowing it to air cool. This relieves stresses from the forging process and refines the grain structure.
Following normalization, harden the jaws by heating them again to just above the critical point and then quenching them in oil or water, depending on the type of steel used. After hardening, temper the tongs by heating them to a lower temperature (typically 400-600°F) for a period of time, followed by air cooling. Tempering reduces brittleness and improves toughness, making the tongs more resistant to cracking and breaking.
What are some common mistakes to avoid when forging box jaw tongs?
One common mistake is not properly preparing the steel before forging. This includes ensuring the steel is of the correct type and size, and cleaning off any rust or scale that could interfere with the forging process. Failing to do so can lead to poor weld quality, inconsistent dimensions, and a weakened final product.
Another common mistake is overheating the steel. Overheating can cause excessive scale formation, grain growth, and even burning of the steel, making it brittle and prone to failure. Always carefully monitor the temperature of the steel and use a pyrometer or color charts to ensure it’s within the optimal forging range. Maintain good hammer control and a consistent forging rhythm to avoid cold shuts or other defects.
How do you customize the box jaws for different workpiece shapes and sizes?
Customizing the box jaws of your tongs allows you to create specialized tools for specific tasks. This involves carefully shaping the jaws to match the contour of the workpiece you intend to hold. You can use a combination of forging, grinding, and filing techniques to achieve the desired shape and fit.
When customizing the jaws, consider the size and shape of the material you’ll be working with most frequently. For example, if you’re working with round stock, you’ll want to create rounded recesses in the jaws. For flat stock, you’ll want to create flat, parallel surfaces. Ensure the jaws are properly aligned and that they provide a secure grip on the workpiece without damaging it.