Rugged As Iron Works

Rugged As Iron Works Self-taught blacksmith, metal fabricator, welder, machinist and leather worker. Commissions welcome.

I have been cold-working metal for over twenty-five years and blacksmithing for over fifteen years. I started blacksmithing because I was no longer satisfied with just bending sheet metal and wire. I wanted to make things from steel like knives and tools that you simply couldn’t do cold. Because I started learning how to blacksmith before Forged in Fire became popular and blacksmithing became cool

, there wasn’t the same resources available as there is today. Consequently, I am a self-taught blacksmith and this has always been a hobby for me. It took time to acquire the skills, experience and equipment necessary to produce high quality axes, knives and other forged items. It also helps that my workshop is where I go to unwind, get some exercise and make something physical; it’s a great break from a desk job. As I slowly approach retirement, I am also happily looking forward to spending more time pounding hot metal. I lean towards the bladesmith variety of blacksmith and prefer making axes and damascus knives. I have made about 200 axes and hatchets over the last few years, which was unexpected as I started making them only to recycle my overflowing pile of leaf-springs. I make bearded axes as I find the broad-headed style more impressive than a regular axe, and they excel at chopping and carving while still being good for splitting wood. Some of my more recent axes are made from railway rails, because there is just something satisfying about making an axe out of something that used to hold up entire trains. Over the years I have made around twenty knives, half mono-steel and half damascus, as well as four swords. I love making the damascus knives as the patterns that form are elegant, and so interesting to the eye. The coolness factor comes from knowing the knife you are holding is made from two different steels forge-welded together, folded and hammered over and over until the two steels are intermixed in hundreds of layers. Damascus is also a challenge, because while I can make a mono-steel knife with a grinder and a propane torch, you need a really hot forge, the right metal and the know how to make a damascus knife and not all smiths can do that. You also need a really big hammer or a really big arm, preferably both. However, given the large time commitment damascus knives take (10-20 hours) I tend to only make them only by commission. I also make a variety of other things or provide metal fabrication and machining services when requested or as time permits. I make decorative hooks for hanging things, rounding hammers and other blacksmithing specific tools and equipment. I can cast aluminum as belt buckles or hard-to-find tool parts, and brass for knife guards. I fabricate metal artwork, plant stands, and small items by request. I also perform small welding and metal repair jobs at request, although I am not a licensed welder. I take pride in my work, and I offer a limited warranty with all my products. if you manage to break a product through normal wear and use, I will do my best to repair it at no cost or at a reduced rate.

09/02/2026

Making a Wakizashi Part Two, the long version

From short shaped steel to hardened, tempered and polished blade. With bonus fire!

Introducing an easier way to watch flaming blades and glowing steel: YouTube!
08/17/2026

Introducing an easier way to watch flaming blades and glowing steel: YouTube!

Quenching a Wakizashi short sword (with clay for a differential hea...

08/17/2026

Quenching the wakizashi short sword in Parks 50 quenching oil, a wee bit more flame than expected.

08/12/2026

Making a Wakizashi Part 1, the SHORT version

08/06/2026

Forging a San-Mai Wakizashi

Prepping, forging and rough grinding a Wakizashi. The blade is made in San-Mai style with wrought iron cladding sandwiching a high carbon, 263C steel core.

Next step is heat-treating and then still more grinding.

Cooking a cooking griddle during a cooking hot week.It was another 30+ week and too hot for forging. So I finished a cus...
07/13/2026

Cooking a cooking griddle during a cooking hot week.

It was another 30+ week and too hot for forging. So I finished a custom carbon steel cooking griddle for a customer that will fit on a round charcoal BBQ or a barrel BBQ.

A short simple project, I cut a 21.25” circle from 3/16 plate using a strong magnet and a wire connecting the center and my plasma torch -something a CNC plasma torch would have done great if I had one- and then cut some hand holds that double as oil drips. I welded on lips to prevent the fat running to the middle and then ground off all the mill scale to bare steel.

The last step was to melt (cook) on some beeswax to pre-season and prevent rust, by way of a convenient, surprisingly multi-purpose w**d burner :)

07/03/2026

Testing out the rear differential side project…works!

Too hot to forge, so finishing the side project.I was going to forge out some blades this week, but we got a heat wave i...
07/03/2026

Too hot to forge, so finishing the side project.

I was going to forge out some blades this week, but we got a heat wave instead, with temps up to 35C without even running the 1200+C forge…

So I decided I would finish the rear differential side project for the go kart instead.

I measured and modified the go karts rear frame to accommodate the differential, added support bars, tacked on the bearing blocks from last week and then made sure everything fit before welding it all up.

Then I spent some time machining the rear axle pairs by sizing and threading them on an old (but new to me) atlas hobby lathe with a suitably ad hoc setup-this was necessary as they didn’t fit in my other metal lathe. Then I welded the axles onto the splined shafts I made earlier, In a way that could be easily cut and moved.

And then it was assembly time. I assembled the new rear axle with diff, bolted it all to the rear half frame and sized the drive chain. Then I reattached the rear half frame, shocks and put in the tires.

Some quick tests and I was confident the rear axle spun and the diff was working, and took it for a spin…and the go kart can now do a U-turn in half the original space without slowing down.

Speaking of slowing down, I should probably add rear brakes-another side project! But not until it cools down a bit more!

06/22/2026

Testing the DIY bearing blocks I finished tonight. They’ll end up welded to a go-kart frame to support the differential and rear axle.

Side project two times removed, or making go kart parts while waiting on steel to arrive.I put in an order for $540 of s...
06/22/2026

Side project two times removed, or making go kart parts while waiting on steel to arrive.

I put in an order for $540 of specialty steel (263C), belts, handle material and quench oil a few days ago -who says blacksmithing is a cheap hobby?- and while waiting on the order, decided to work on the go kart differential parts.

Specifically I needed two bearing blocks in an unusual size to weld to the rear sub-frame to hold the differential in place. As this will support the rear axle they have to be sturdy and inflexible. So I made them out of 3/4 steel plate of which I had only a small piece.

So, I plasma cut them out, tack welded them together to make them match , then machined all four sides, and notches. Cutting the concave section was tricky, but I used a fly cutter with a carbide cutter that was precisely the right radius and machined it to match the bearing. Last step was to drill 3-8 bolt holes to clamp them in place later.

And a quick few spins to test and they are all good, and ready for welding to the subframe later.

Address

Angus, ON

Opening Hours

1:30pm - 10pm

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