Fold Forming Sheet steel - basic introduction for blacksmiths

Fold forming steel was my planned topic for the failed live stream the other day. Since that didn't work out, I thought I would go ahead and make a regular edited video on the subject. These are only the basics of the idea since I have done very little fold forming myself.
My name is John Switzer, I operate Black Bear Forge, a small one person blacksmith shop located in southern Colorado. My current focus is shifting away from commissions and customer orders and towards education through these videos on KZbin. Thank you for watching
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[@candlerpainting]

That`s really cool. Probably something I`ll try. We had a good time watching your videos over the weekend. Thanks so much.

[@BlackBearForge]

Have fun!

[@johncatt1867]

This is Freestyle Forging at its best.

[@scotthaddad563]

I watched an architectural blacksmith in Atlanta at the King Plow building while he worked on a very large crab sculpture. He had a cut out in a heavy piece of steel that was the shape of the shell back to which he tacked his piece to be formed. With a rosebud torch in one hand and hammer in the other he selectively heated the area to be worked then pounded away until the domed back of the crab shell was formed. He then cut the form loose from the heavy iron and ground to final shape. This guy had some amazing pieces that he was working on including an all copper stair case with an Octopus entwined in the balusters . I can’t for the life of me remember this artists name.

[@moreybandel5560]

Interesting stuff! Thanks, John. More ideas!

[@stormyeffects4795]

Hey John, I was one of the first 10 people in the live stream. I waited it out the whole time and I still think it was worth it. Don’t stress about things like that. We are going to be fine, you are going to be fine. I’m glad you put out this video because this really was a technique I wanted to see. Thank you for being so inspirational. No matter how many times you get back up from a little mis-step, all of your viewers are still here to help you back up if you need. Thank you for all of your hard work- Storm Ps, I must go make a leaf now

[@Smallathe]

NICE dish, loved the method!

[@grandadz_forge]

This is a whole new facet of design. Thanks for taking us there.

[@thomasarussellsr]

Might be a good way to strengthen individual plates for plate armour as well.

[@rlgroshans]

I love the look of these. Thank you for sharing.

[@BlackBearForge]

Thanks for watching!

[@mistaben59]

Love the sculptural element this adds. Keep your positive vibes coming John. Love it!!

[@johncatt1867]

They say Art is in the Eye of the Beholder, and I am Beholden that this is most definitely Art. Thank you for sharing this with us all.

[@larrystrayer8336]

The fold forming video is a great reminder something I haven’t done in years. I was looking for something different and also easier on my shoulder thanks

[@BlackBearForge]

Glad it was helpful!

[@thomasarussellsr]

Easier on the shoulder depends on the thickness of the material, I would think.

[@Gremlins422]

Thanks John!

[@shirlmiester]

cool video and music, thanks

[@rognavolter]

You are a well rounded artisan sir

[@hammeranvil2374]

You are awsome John

[@NordicEdge]

Interesting textures. Thank you for another good video! Bjorn

[@picklesnoutpenobscott3165]

Thank you for getting this info out to us.

[@josephmaschari1073]

Thanks for the video on folding. I was hoping live stream would of happen, but a lot of chat was going on. Looking forward to the next one.

[@pjamestx]

Another great exploration video, loved the outro music too!

[@BlackBearForge]

Thanks 👍

[@MrDukaman]

Pretty cool idea. Ever try soaking the rawhide mallet in water. Makes it a little heavier and doesn’t burn as much. Too bad the live stream didn’t work.thx John......Paul🔥⚒🇺🇸

[@gustavorampazzo9934]

Sorry for the problems with the stream, hope you're luckier on the next try! Thanks for the videos!

[@JoeGassen]

Please keep trying on the live stream! Your content is the best in the blacksmithing community.

[@davidsmith3828]

Great ideas, simple techniques! Looks like a good project for me...the beginner! Thanks for posting. I’m inspired to do something!

[@BlackBearForge]

Go for it!

[@ga5743]

Thanks for the education John, as usual you’ve done an excellent job. I love how you offer shout outs to other blacksmith/makers. 👍

[@olddawgdreaming5715]

Thanks for another fascinating video John, sorry your live stream crashed, I could see your frustrations when you had to stop the video. We sure enjoyed this video and the methods you used to accomplish this art work. Thanks for sharing with us, Fred.

[@fn45tacticalsuppressed11]

This technique can make a door knocker. Or some kind of retention plate for rod’s of metal, round bar stock. Possibly in a fence that needs large wire fencing attached to wood posts.

[@marcsenteney3160]

That was worth the wait! Thank you for showing us your adventure in this technique. Well done sir!

[@paulorchard7960]

Been waiting for this since the internet fail a few days ago! Great to finally see and I have just been gifted more than one idea on where to go with this forming. Thanks John, be sure to see you on livestream sometime soon!

[@BlackBearForge]

Glad you enjoyed it!

[@jeffgrier8488]

Thanks for the video John, it triggers a lot of ideas!

[@BlackBearForge]

Glad you enjoyed it!

[@adelheidsnel5171]

I love it!!! Very beautiful freeformed. Artistic❤️

[@BlackBearForge]

Thank you so much!

[@NeilGraham.I.M.F]

It's too bad the live stream didn't work out. But it's a learning experience. And a door knocker plate was exactly what I thought about the cross

[@ElseeKay]

16:01 legends say the spiciest taco was hammer forged

[@Gremlins422]

It even sounds like a taco shell!

[@Moondog-wc4vm]

made in the chilli forge too!

[@stuffbywoody5497]

A couple of things occurred to me watching this. 1, I need a couple of rawhide mallets, fold-forging/forming has it's place in blacksmithing. Thank you for sharing with us John.

[@frankgaletzka8477]

Hello John It is not your fault that the life stream dont work You Made the best of it and do a Video that is very good It is amazing to see how you create Art with a peace of metal a fire and a Hammer You are a very creativ Man of course you say ahh its only basic nothing else but for me and i Think many others it is wonderfull You have inspiriert me Thank you for that Stay healthy and all the the best wishes to you and your wife Yours Frank I

[@picklesnoutpenobscott3165]

We do live meetings for our woodturning club. Sometimes it is wonky, but usually it is ok. Thanks for sharing what you know.

[@markmoreno7295]

I liked the end views of all the finished work and I liked the Harry Potter-like music! Kind of made it mysterious or magical.

[@clydebalcom8252]

Awesome tutorial as always.

[@BlackBearForge]

Glad you liked it!

[@gurvinderkau1e5w18]

Playing with scrap is best way of learn . So much fun heating hammering folding opening. Great video👍👍👍👍

[@BlackBearForge]

Thank you 🤗

[@waskasoometalworks3329]

i had to try this today with some 3x5 inch 1/8 flat bar. it is tricky to get it straight and open up properly, but after a few tries and a few fails it looks fantastic. i must admit it is a really cool thing to learn!!! thanks for this video good sir!

[@johnjude2685]

It's art, good idea, I think it is a fine dish. I'd try to hammer it in its center area with a cylinder with rounded edges while hot to provide a flat center to prevent rolling in use. Thanks for inspiring Sir:

[@thomasarussellsr]

But that could flatten the ridge as well... just a thought.

[@TufStockdogs]

Thank you John that is very interesting thank you for showing us this

[@Lesnz2009]

Back using the gas forge today, cool...teh big oen reminds me of large leaf and I certainly would find a use for it outside a forge. Thanks for sharing

[@devilstailforge4142]

I love making folded metal bowls

[@calebstiegler1017]

Charles Lewton Brain, regarded as a master goldsmith, is who I learned foldforming from. He has some videos and books on it I believe. The video I watch was really old but still very good on the teaching of foldforming.

[@marcerivest6204]

I like it, never thought of doing anything like that. Thanks again John

[@BlackBearForge]

Very welcome

[@johnjude2685]

About the drill brass wheels some are steel under a thin brass coat and I will say."thin" , So watch what you buy. Nice teaching again Sir

[@monkeygjluffy4487]

I think there's some practical use other than decoration, I started to think at the medieval armour with all that fold in the steel and maybe was done in this way, and that fold help the rigidity of the plate. Sorry for my crappy English

[@thomasarussellsr]

I was thinking rigidity and strength in armour as well.

[@BlackSunCompany]

You're absolutely correct on this. Fluting (applying multiple parallel folds like we see in this video) started showing up in armor around the 16th century if I recall correctly and became popular due to the added strength against crushing by maces. The curvature adds strength in the same way you can take a sheet of paper, give it curvature, and hold it out against the pull of gravity or other force. Tape measures are curved for the same reason. It's both functional and aesthetic.

[@hendrikvanleeuwen9110]

Yes. It is called 'fluting' on plate armour and was done for functionality. If you start looking you will see it in Indo- Persian equipment and even Roman helmets, too.

[@davidhillman7004]

Love this

[@hiluxmad]

Interesting technique thanks for the video . I like the new layout behind you . your layout tools are like art

[@BlackBearForge]

Thank you very much! I'm glad someone noticed the change

[@paulpoppe8845]

Nice tools on THE wall

[@BlackBearForge]

Thanks

[@ericdouglas9804]

A really “in” forming video 😎 I was there for the live stream and really felt bad for ya. I hope if nothing else, this pandemic shows the importance of high speed internet available to all; as it seems it’s becoming more important for education. Thanks John

[@markmcmeen287]

Another great video, John. Really helpful to see your trials with different thicknesses. Also, helpful suggestions for applications of the fold forming. And on a totally different subject, I hope your big botanical project is still in the works. Looking forward to seeing how the components come together. Thanks for the teaching and encouragement!

[@BlackBearForge]

It is

[@Malfeasance455]

Had a perfect lily pad leaf there for a bit.

[@TheOldaz1]

I guess it's fold forming, I used the same process to create tie-downs for the floor of my truck bed, just added "D" shaped eyes to fit the fold and bolted them to the floor. Thanks John.

[@thebasicsofcooking4633]

Thanks good info

[@manuelalmodova3137]

hi MR SWITZER I enjoyed your video one thing i do when fold forming i use a round piece of stock where the spine or fold is at i use different sizes of stock it protects the spine also if you look at some videos of CHARLES LEWTON BRAIN there is some amazing copper smithing work that could be used forging iron thank you i always enjoy watching your videos.

[@marcogallazzi9049]

It just occurred to me it could be a good idea to make an iron book with this technique, something with weight to hold books in a shelf.

[@BlackBearForge]

Great idea

[@Moondog-wc4vm]

I love the idea of book shaped hand forged Iron bookends for my shelves!. Do you mind if I adapt your inspiration for my home?

[@marcogallazzi9049]

@@Moondog-wc4vm Of course I dont. I hope they turn out great! I will give it a try myself once I'm out of lockdown and can go to my shop :)

[@Moondog-wc4vm]

@@marcogallazzi9049 Thanks! I'm going to give this a try as soon as possible. I hope to get to the forge at the end of July 2020, when I will be making some chisels. As soon as they are done I will be trying this idea. I'd like to make them as ornate and Gothic as possible, like grimoires from an old novel. I'll try some stamping and chisel work as well as the folds, to try to re-create that 'Frankenstein' feel. I really appreciate your willingness to share what was a really artistic original idea. Good luck with yours, and I bet that our final outcomes are very different from each other. Thanks again.

[@shortfuse43]

Really nice looking cold forming! I had never seen that done before, thanks for doing the demo. As an aside, if the smoke is bothersome, just slap a little water on the stump. It'll soak in right away on the end grain and won't significantly cool the hot work...and, no smoke!!

[@shortfuse43]

Sorry! For some reason, this comment double posted about a minuted apart...must have been gremlins.....

[@adamkerr1660]

I think this technique would be great for making a serving dish or something of that nature, with the folds being little dividers for food

[@timjackson5555]

Took a class for leather lined copper sheaths that were fold formed then silver soldered. I think steel is done for botanical forms mainly. Haven't seen it on anything else other than some small sections on ironwork like corners etc.

[@thomasarussellsr]

The next step is a forge fold formed turtle shell, then a metal drum, tuned and all (think Jamaican music). Love the leaf, the cross, and the dish.

[@thingmaker3]

"Not having a preconceived plan" is how Mr. Lewton-Brain cam up with this stuff! He says it's vital to take time to just play around. In regards to how much work is needed vs thickness of material, an engineer buddy of mine tells me rigidity is proportional to the third power of thickness. If that's true, 3/16" would take more than three times the effort of 1/8" (Does that mean we can charge three times as much for it?) Thank you for another excellent presentation!

[@ScrewDriverxxx]

I joined your live stream and not too upset it didn't pan out. Disappointed for you but equally happy to catch up later. I wonder what additional features you could provide during a live stream and what sort of demonstration would make the best use of them.

[@johnjude2685]

Perhaps a bottom for the draw to separate kitchen forks, spoons and knives, Or to separate all the chisels that now I have. Thanks for teaching Sir

[@georgem7965]

With the heavier material you might try catching the first fold in the vice as you do with the second fold. I think that would be a little faster and easier and could be done in fewer heats. BTW, I hope to meet you in person when it is safe for RMS to go back to live demos. George M. Westmarch Forge Laramie, WY

[@spookiefish659]

hi John, thanks for the demo. i had no idea this was even possible in steel! check out Charles Lewton-Brain's book on fold forming. he is a jeweler and i think is credited with inventing the technique.

[@williamsultana3848]

Hi John

[@brysonalden5414]

Thanks for another instructive video! I assume the piece was still warm when you hit it with the brass brush; I haven't gotten much brass effect when I've tried it cold.

[@BlackBearForge]

yes it was

[@songman0]

I think that better results cn be made with making a V or U notch dye and opposite dye but this will work only to 2 mm thick sheet steel I think. Similar method use sheet metal manufacturers to give a bending strength to thin sheet metal plates (all car bodies is make on that philosophy, sometimes a layers of paint and other coatings is thicker than sheet metal) It is very nice video.

[@BlackBearForge]

Once you go to a die you are die forging as opposed to fold forming. Two completely different approaches

[@erikjoven2388]

Very cool - i wonder if you could make one of those that appears to have a weave pattern. Because the 2nd fold appears to be over top the first fold (and it sort of is) you could maybe take a square sheet - break it into horizontal and vertical quarters - and start doing top quarter (horizontal) and then unfold. Then do left quarter (vertical) and unfold - then do top half (horizontal) and unfold - then do left half (vertical) and unfold - etc. - i think that would give a really cool "weave" pattern on the sheet with 16 sections. I'm not a blacksmith - but would love to try that out.

[@BlackBearForge]

I don't think it would come out just right because of the way it folds, but worth a try. Even doing it in paper might give the answer.

[@Zogg1281]

Finally!! The giant chain link is mentioned! Please tell me you weren't commissioned to make a whole chain of those........ or mabey miss read what the client wanted...... ? I'm not sure which one would be worse 😂 Those fold forming bits are awesome! I love the cross the most, but the bowl is amazing too. You might have just made a few prizes for something in the future 👍

[@BlackBearForge]

Just a single link purchased at an auction many years ago.

[@Zogg1281]

@@BlackBearForge Ok, the UK auctions officially suck! I've been looking for anything blacksmithing wise at my local auction for about a year. The worst bit is that I know blacksmiths who have got some great finds at the same auction place. I'll just keep looking and one day my favourite style of anvil will be there......... double horn like the one you have by your bench. Real happy to find out a little about the chain link 👍

[@blackgriffinxx]

I think this is one of those skills that just fall out because we can made some thing better. Still this has it use . A fail point in place. You want a fail point Adding strength to things to some things. Making a bracket. As you said it mostly a decorative kind of thing now. Still i can see this used to make a lock box.

[@garywilliams8554]

you know what hook you never did make John?.... a bale hook . I used one a lot as a kid :)

[@RayFromTheHayclan]

You could bend out the smaller one and make a drawer pull. Cool forms though.

[@boldrobin5709]

I can see some belt buckles

[@richardbyerssr5057]

If ya had some wider sheet steel they would make good open fire hot dog cookers with two hinged together in a tong style grip welded on them!!

[@zippe43467]

if you are still reading the comments on this video, could you please do a little short on your rawhide mallet, I would like to make one similar, as it seems to be a great way to add some weight to an otherwise light hammer.

[@lm4278]

I really like that cross you made. If you offered that for sale, I'd be interested.

[@BlackBearForge]

Actually, I still have it and would be willing to sell it. The price would be $30 plus shipping. If you're interested send me your email and I can get a paypal invoice out

[@robertlunsford1350]

13:37: The forbidden taco.

[@billssmithy7352]

Neat to watch, one day I'll try it. A question: What are the differences and or advantages of using a wood vs. rawhide mallet? I've only a wood mallet, which I made from a deadfall oak limb in my backyard.

[@BlackBearForge]

Rawhide is probably longer lasting plus the ones I use have heavy steel heads so they tend to be heavier hammers than a similar sized wooden mallet.

[@jimhumphrey]

I'm seeing a tortoiseshell in there.

[@paulorchard7960]

Jim Humphrey Yes, another idea!

[@Redneckemtb]

That's what I was thinking also

[@farmerboy916]

I rather suspect that by the time you get to the end of the tortiseshell pattern, it'll be both incredibly difficult to bend and incredibly difficult to not crush older folds. Maybe just working it on a stump with a mallet, because you don't need the sharper folds. Still, very intriguing. It occurs to me that maybe, a small custom raised face style hardy tool (ala a stump anvil) with heavily radiused edges might be just the thing for supporting between the folds if you want kind of consistent 'tiles'

[@waskasoometalworks3329]

dude, build one and then share it. that is a wicked idea!

[@fouledanchorforge5223]

Me too

[@521cjb]

Paper airplane made of mild steel, how far it flies depends entirely on the strength of your throwing arm.

[@BlackBearForge]

I like that idea

[@duanecjohnson]

Hi John; Would a narrow swedge be helpful when unfolding? It would seem that would support and preserve the original fold.

[@BlackBearForge]

It would be worth trying out

[@waskasoometalworks3329]

try a wide mason's chisel. worked good for keeping things consistent today

[@augiezehner6059]

How do you keep the cross with the bronze on it from rusting after you finish making it?

[@codytradingcompany7798]

Augie Zehner You could hit it while it’s still hot with paste wax or other preferred oil while it’s still warm. Or you could always spray paint it with clear

[@BlackBearForge]

I go the paste wax route myself

[@augiezehner6059]

Thank you very much!

[@dtdonoptics]

Check out Charles Lewton-Brain fold forming videos

[@biggin0317]

I'm not sure of this question has been asked and or answered but would a wooden mallet work too?

[@BlackBearForge]

Yes, they work quit well if they are large enough.

[@dicksargent3582]

Info on fold forming can be found here www.brainpress.com/ Charles lewton-brain is the largest promoter of this process and arguably the inventor/discoverer of this technique.

[@jonandersen3347]

just curios how the bottle room is looking

[@BlackBearForge]

Moving along very slowly. But still in the works

[@DavidWJoyce]

just wondering john - have you ever forged solid copper rod or bar stock - wondering if there would be issues with the hest - burning or other such problems?

[@BlackBearForge]

I have not done any copper forging

[@calebstiegler1017]

Forging copper can be done in a forge by simply turning the forge down or placing it on the outer edge of the forge where there is less heat. Copper can be heated with a hand torch as well. Copper doesn’t have to be hot to forge until it needs to be anneal from hardening cause from forging. Copper is very easy to melt in a forge.

[@klkkylekin5948]

Can I do all the folds first then unfold all at once

[@BlackBearForge]

You can certainly give it a try.

[@klkkylekin5948]

I will let you know how it goes

[@rogergadley9965]

Is fold forming used in a functional way, or is it always used to create an aesthetic or artistic effect?

[@BlackBearForge]

For my purposes it would be mostly a decorative element for a project. But it does add stiffness, so that could be a functional requirement in some work

[@rogergadley9965]

@@BlackBearForge Thanks.👍

[@Nightfoxx21]

Looks kind of like a turtle shell

[@scottswineford6714]

I'm a year late but I don't watch Livestream anyway. My internet has yet to stay up for one regardless of source, time, region or desire.

[@jk141982]

blacksmith tic-tac-toe! for grandkids

[@BlackBearForge]

Great idea

[@PaulMSabol]

Couldn't you use a die or hammer the sheet over a rod?

[@BlackBearForge]

You could, but it would be a different technique and not fold forming

[@azurexeruza]

If you're looking for origami out of sheet steel lemme know haha though... To be honest I haven't done a swan yet...

[@donstash4295]

PARTS for a rat rod.

[@kenstaggs4582]

Test designs and practice with aluminum foil 😉