Follow us, Into the Fire…

I love to stay in the fire as much as I can by forging out all of my stock. Forging is a manufacturing process that I choose to do in order to give my clients a product with more distinct strength by forging the metal. I build a one piece spur and one piece mouth ports. I take pride in every piece that I build, and I aim to create artistic tools that are durable and yet functional for your everyday tasks.

Stage1Stage 1
I start off by heating up my metal to a certain temperature so that it becomes easier for me to forge out. I prefer to use a coal forge verses traditional propane forges to heat up my metal because I can obtain a hotter fire resulting in a more consistent heat treatment. With an electric blower on the side, I can regulate the air flow to coal through the bottom which helps me achieve the desired heat temperature.

Stage2Stage 2
Each Spur is originated from a piece of 4140 round stock. 4140 is a high carbon steel that allows you to use water or oil to quench your steel to achieve your desired tempering hardness which helps prevent your bands from collapsing and, therefore, gives you a stronger product.

Stage3Stage 3
Preheating the metal to the desired temperature before it is worked helps me to develop the shaping of the metal, and further enables it to take multiple heats as necessary. In layman’s terms, sometimes I will have to go back and forth between the trip hammer and forge to re-heat the metal. By keeping the proper heat treatment, it allows me to forge out my metal enabling me to continue shaping it without impairing the integrity of the process or the metal.

Stage 4
Once I get my metal to its desired heat, I carry it over to my trip hammer, which is a large, heavy power operated hammer that releases a forceful pounding on the metal being worked.

Stage 5
I use basic forces to move my metal by manipulating the heat along a long piece of steel.

Stage 6
By hitting the metal accurately in the desired area and applying the heating techniques, I am able to draw out the metal by compressing it together under great pressure forming a flat steel bar, giving the product a distinct strength in return.

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Each spur is divided into two even sections that are created by splitting the flat steel in half. Once the steel is split, I beat the crease out from the back of the shank to form one solid band so there is no weld holding the shank on, which in turn gives you a one piece spur. With the flat steel being split, I now have a band and shank formed.

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At this stage, I shape the heel bands which can cause stress cracks (also known as forging cracks) next to the shank where the metal is being stretched. These stress cracks do not affect the spur’s durability by causing them to become weak or brittle, nor do they show up on every spur. They are strictly forging marks that will show up randomly due to the hardness of the metal being stretched that sometimes occurs during the forging process. Once the heel bands are shaped, I then roll the shanks and heel bands by hand filing them. Then I attach the hangers and insert the spur rowels. This sums up my 8 step design process. Once in the raw stage, I move on to the silver work and polishing.

My fees are based on hours and materials. The forging skills, and blacksmithing techniques that I apply along with the intricate silver work and detail finishes are very time consuming and can take several weeks for proper completion of a product of the quality that my customers deserve.

When an order is placed, I provide a projection of the anticipated cost and I do not exceed that projection. The projection that I quote does NOT include sales tax and/or shipping and handling costs.

For any inquiries, you can easily get in touch with me via telephone or e-mail. All of my contact information can be found on my contact page.

I greatly appreciate the time you took to review my design process!