Hot Iron Muster 2005

Springtime signals rebirth, and September’s Hot Iron Muster was right in tune with a fresh look at the fundamental processes and techniques of blacksmithing. Since its inception in 2000, organiser Alan Ball has developed the “Muster” into a unique skills development opportunity for Australian blacksmithing enthusiasts. For 6 days each year, his smithy in Logan Village just outside Brisbane takes on an international air with a guest blacksmith providing hands-on instruction and an insight into overseas events. “Inviting international instructors to share expertise and ideas adds diversity and depth to the creative talents of Australia’s own craftsmen” Alan believes. “We may live in a world where information is only a mouse click away, but there is no substitute for having a skilled mentor to guide your hammer blows every so often.”

Guest instructor for 2005 from Santa Fe New Mexico, Frank Turley has himself been instrumental in facilitating a rebirth of blacksmithing after its virtual demise in the first half of the 20th century. Since opening his school in 1970, he has taught a steady stream of students that includes many of the best-known smiths in the USA today. In addition to his own courses at Turley Forge, Frank’s influence continues to spread through his regular invitations to instruct at blacksmithing schools and conferences in the USA, Canada and Central America.

Having attended a week-long class with Frank at the John C. Campbell Folk School in the USA a few years ago, Alan knew he would be an invaluable instructor for the knowledge-hungry local smiths. On his first visit to Australia, Frank was keen to help build the developing skills base. "I enjoy teaching, because I had such a difficult time learning to use the tools properly and working in sequential steps. I enjoy sharing what I've learned, because in so doing, I am trying to make it easier for the student."
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Even as the craft gains recognition as more than nostalgic re-enacting, its ‘Old World’ processes seem in danger of being relegated to less importance than the end result. With his boundless knowledge, technical expertise and passion for working hot metal, Frank proved to be the ideal leader to revisit the journey of creation that is the magic of blacksmithing. An eager audience of both aspiring and accomplished smiths settled in for the Demonstration Day which traditionally opens the ‘Muster’. Frank’s teaching prowess shone with an absorbing commentary to accompany his forging projects. In addition to describing what he was doing, he also talked about why he chose to do it that way, as well as the implications of other courses of action.

A discussion about that most basic of tools – the hammer - covered a variety of grips and their impact on the smith’s arm while performing different movements. Hammering out delicate rose leaves (from the pieces of 8 mm round bar that he first forge-welded together) enabled him to explain where to place his hammer blows and the amount of force required for the task. He explained the importance of knowing what actually happens to the stock as it is being heated, which is the hottest side as you bring it out of the fire, and how to place it on the anvil to ensure a steady aim when hammering. With the vagaries of forge welding presenting a common challenge for many smiths, he demonstrated a variety of rollovers and scarfs, all accompanied by a thorough explanation of technique, including different systems of striking.

To highlight the versatility of simple design elements, Frank worked through a repertoire of scrolls, pointing out how the negative space around a scroll governs the visual impact of the finished article. Careful to not have “too many irons in the fire”, Frank maintained efficient use of the heat by forging a scroll jig along with his samples of fishtail, penny, split end, chamfer on edge, rolled leaf and so on. Time spent taking heats was also put to good use with recommendations for taking care of your own body. Emphasising the role of warm-up and warm-down exercises, Frank demonstrated stretches for legs, wrists and shoulders, as well as stepping through some Tai Chi and Qi Gong movements designed to improve balance. He obviously practices what he preaches, as Frank showed no ill effects from his long-haul trip. This captivating day of blacksmithing infotainment was delivered just 24 hours after his arrival in Australia.

The next morning saw the start of the week of hands-on instruction focussing on Toolmaking. With notebooks at the ready the class participants collected around the main forge for the start of Frank’s demonstration on making a pair of flat-jaw tongs with forge-welded reins. While the fire was warming up, the drawing board began to sprout sketches and measurements as he outlined the process involved. When each step was completed in the forge, the next took shape on the drawing board, right down to showing placement on the anvil, angle of blows, and heat colours to watch for. With instructions in hand and Frank’s reminders “Don’t put cold iron in a cold fire” and “Always leave a finishing allowance” ringing in their ears, the class participants were soon hammering out their own tongs under his watchful eye.

Each day saw a new tool providing the opportunity for Frank to lead his students further into that magical ‘journey of creation’. With the purpose of the tool dictating the metal being used, he was able to work through the properties of the different types, how they suit different applications, how to forge them, and the processes and results of heat treatment. His demonstrations really brought the explanations to life, and the students followed through to unfold the same exercises in their own forges. Metallurgy had never had such a life of its own in their minds.

Frank’s plentiful supply of anecdotes ensured a lively pace to the sessions, and he also slipped in the odd ‘trick’. In between projects, he heated a section of 40mm diameter coil spring, and dropped it over a rod held upright in a leg vice. Gripping the bottom end, he backed away straightening out about 2 metres of the steel, which was then used to make lightweight scribers.

Although coke was the main fuel used in the forges, a supply of charcoal was consumed each day to get the fires started. Some of the participants also opted to use charcoal exclusively, necessitating a ‘burn’ during the week to replenish supplies. Having a good source of Eucalyptus trees on his own property, Alan always has a ready supply of timber. He filled his 4ft x 3ft x 3ft purpose-made steel bin with small logs and soon had a strong blaze. After about 2 hours, the bin was topped up with more logs and the lid closed to choke out the fire. Left to smoulder for 24 hours, the charcoal was then ready for use.

Keenly interested in tools of all shapes and sizes, Frank closely examined all the leg vices in Alan’s workshop over the course of the week. According to his past research, the shape of the mounting plates and presence of u-shackles on the staples indicated that most were relatively modern, manufactured in England towards the end of the 19th century. One however caught his attention with its forge-brazed internal screw and screw box suggesting that it had been made around 1800-1830. He was also interested to note the predominance of English anvils, with a 290lb Hay Budden the only ‘foreigner’ among the mainly Peter Wright population. Australian anvil manufacturers were also represented with a 160lb Bradford & Kendall, and Alan’s own VS brand 165lb anvils cast locally from high tensile steel.

The week drew to a close all too quickly. With the fires finally extinguished and the tools back in their racks, the workshop participants showed their appreciation for Frank’s leadership by presenting him with some unique Aussie mementoes. Another successful Hot Iron Muster was celebrated with a cold drink and the warm camaraderie that is so much a part of blacksmithing all over the world.

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