Fred Connell - Blacksmith
I seem to do a variety of blacksmith work. Some is of odd shapes. My propane forge is constructed with dry stacked light weight insulated 2.5"x4"x9" firebrick. A 1" thick heavier more durable firebrick is used for the forge floor. This is a very versatile design since the bricks can be moved around to accommodate unusual shaped work.
I used the Zoeller Forge "modified side arm" burner design. The burner is a 3/4" ID naturally aspirated side draft burner design with a 0.043" nozzle drilled with a #57 drill. A straight 3" piece of 1" iron plumbing pipe is used for a flare. It is not tapered and works fine. It protrudes about 1" past the 3/4" burner pipe. The end of the burner flare is recessed about 1.5" from the inside of the forge. The hole in the firebrick for the burner is flared to the inside of the forge.
The burner body is a 1.5" Ward plumbing "T" reducer to 3/4". I turned the nozzle from a piece of 3/8" brass rod and drilled a 1/8" hole almost through the center of the brass nozzle. I then drilled a 0.043" nozzle opening and tapered the last 1/2" of the nozzle.
The local propane supplier provided the adjustable 0 to 30 PSI regulator and connector hose. All burner parts except the Ward T and the brass nozzle rod were found at the local big box retailer. The Ward T was found at a fire sprinkler contractor.
I usually use this forge with less than 2 psi propane gas pressure. It does not consume much propane.