Blacksmithing

 

In movies blacksmiths look like WWF wrestlers, dramatically slamming white-hot metal with sledgehammers. When I took a blacksmithing course under the guidance of an old pro, the experience was more realistic: A plate-sized fire, small tools and frantic tapping.

The forge this time was an old metal hubcap, with small holes drilled in the middle, and the blower was a refurbished Electrolux vacuum motor. You don’t even need the electricity; on another course we sculpted a forge out of clay and horse manure, and turned some old fertiliser bags into bellows.

We began each day by lighting a small fire in the middle of the hubcap, right over the holes. Once the fire was going, we placed charcoal delicately over it, and then a ring of coal around the charcoal, and the crank fan blew air through the middle to keep the fire hot. Iron-working only appeared in the last 5,000 years or so – the final 0.3 percent of the time humans have had fire – because ordinary wood fire does not heat iron enough to work, and large amounts of charcoal and air are needed.

We quickly learned that you need to spend a great deal of time standing over the fire, with the metal part in just the right place – in the middle, above the blower and slightly buried in charcoal – to get the right temperature. Too little heat, of course, and the metal cannot be worked, but too much and it begins to “burn,” liquefying and sparking. A lot depends on the size of the metal piece – the tractor axel we put in took ages to heat, but I accidentally burned off the tines of my fork in short order.

Once the metal was glowing orange, we had to rapidly move it to the anvil without yanking it out and sending hot coals everywhere, and without burning the people standing shoulder-to-shoulder with you. Once at the anvil you had only several seconds of BAMBAMBAMBAMBAMBAM ... until it was black and solid again.

Also useful are steel vices and hefty pliers, which allowed us to grip metal while turning it – hence the twist in the fork handle. None of us wore gloves, but leather aprons and goggles were recommended against flying sparks and coals.

This time, I took an old car part and hammered it into a straight bar, flattened it into a knife-shape over the next two days, and a bit of cutting and polishing did the rest. I cut a handle from a hazel branch, heated the “handle end” of the metal until it was yellow-hot, and seared the hot metal into the handle, with a gust of steam and a few bursts of flame from the wood.

Blacksmithing is one of the dozens of professions that were widespread until just the last century, now is kept alive only by a few aficionados. For thousands of years in metalworking cultures, smiths were a vital and respected role – look how common it is as a surname today. They might become vital again if the coming decades bring the turmoil we anticipate. With charcoal and tools, a smith could turn landfill scrap and old car parts into useful tools again – and as far as I know, there is no end to the number of times metal can be recycled.

When the world is no longer able to mass-produce new materials at its former rate, when there is no new plastic and fewer forests, we will have billions of tons of landfill waste. Movies like WALL-E posit garbage covering the Earth, but in real life much of that garbage would not only be reusable, but precious. Some of it will be metal, and all the landfills we have created in the last few decades could become our mines in the next few decades. 

Top photo: A forge. Bottom photo: The knife I made.