OPENING THE WATER GATE.—Page 164.
I let on a very little head of water first, and rushed to my fan-wheel. There it was, moving with great rapidity, and the connecting goatskin bag was evidently distended with air. Thence I rushed to the other side of the blast-furnace, where the feeding-place for fuel was, and by casting in small, light objects saw them sucked up the chimney at once. I was successful. I had at least ten times the power that I needed for my purpose. I rushed back to the dam and cut off the water, perfectly content with the experiment without bringing any shock upon my machinery by putting on a full head of water, which I saw I did not need, as my fan-wheel, as I supposed, was turned with the utmost ease, having no resistance except the air. I could do nothing more this day but admire my handiwork, and arrange little matters here and there to perfect the whole affair and get ready for my first smelting of the ore.
CHAPTER XVI.
Smelt my iron and make Bessemer steel and all kinds of tools. Erect an anvil and forge. Build a saw mill, and plant a farm and kitchen garden.
Having gotten everything all ready for my purpose, I placed, as nearly as I could judge, about a ton of the broken ore in my kiln to be roasted or calcined, and after this was accomplished, I transferred it to my blast furnace and added to the calcined ore about a ton and a half of half-burned coal, and one-third of a ton of limestone; these being the proper proportions, as I was well aware. Under this, and around it, I placed a large amount of coal fuel, and having ignited it by means of a large quantity of wood placed under the whole mass, I went, when it was well started, to my gateway on Rapid River, and set my machinery agoing, which started the fan-wheel, which immediately created a terrific blast, and the whole furnace was soon in a glow. I kept this up by feeding new fuel, till by certain signs I felt confident that the mass of ore was smelted, when I shut down my gateway so as to regulate the blast to its minimum and keep the fan-wheel just revolving. I then dug away the clay at the orifice of the blast-furnace that opened into the smelting-room, and had the supreme satisfaction of seeing the molten ore flow out like water into the furrows of sand that I had formed and excavated to receive it. I had made this furrow for a purpose also, and had something in mind when I formed the sand mould, something like a foot in depth and eighteen inches in length, exactly under the nozzle of the delivery orifice of the furnace. The molten ore ran into this rapidly and soon filled it, forming a rough block of iron a foot thick, a foot wide, and eighteen inches long. When the fiery fluid had completely filled this, I shut off the discharge by thrusting some moist clay into the orifice. This block that I had just made was to be my anvil, and as it was large and would take time to cool, I directed the orifice of the furnace to one side by means of a clay channel, so that the next discharge should not interfere with it; and as my desire was now to get steel in smaller quantities so that I could use it, I drew narrow and shallow channels through my sand at quite long distances from the blast furnace, but all coming together in one deep channel under the orifice, but spreading to different parts of the smelting house, as the ribs of a fan do from the point at which they are collected. Into these channels I allowed the remainder of the molten ore to flow, and it extended itself through all these minor channels, and when it was cool I had several long bars of cast steel that, on my anvil, I could work up into any form.
After a few days, when my anvil was perfectly cool, I mounted it upon a block of wood and commenced to build a forge near by it, of brick and stone, into the fire-place of which I led a branch flexible tube of goat's skin from the fan-wheel, which I could easily detach and connect, and which gave me a blast instead of the usual bellows. At this forge I worked for a week steadily, turning out the simplest and most necessary tools, such as chisels, hammers, hatchets, axes, nails, bolts, plane irons, gouges, etc., which I tempered and hardened when needful. I also made myself tongs and shovels, pickaxe, and crowbars, and as fast as one tool was made at my forge, such as a pair of tongs and a hammer, I had means to make others better and rapidly. In this week I saw treasures gather up about me fast, and, having finished my iron work, I set to, to arrange them into tools. In the first place, by means of cold chisels, I cut out from a large mass of soft stone, that seemed as if it would suit my purpose, a grindstone some two feet in diameter; this I set up on two standards and connected with my water wheels. By means of this I could sharpen and bring into shape all the rough pieces of iron tools that I had forged out, and I had no difficulty in sharpening all my axes, planes, hatchets, chisels, etc., and, when necessary, giving them a finer edge on a whetstone, which I had found to suit my purpose. After getting these all in shape, my next task was to affix handles to them. This was not difficult to do, and it is hardly credible how soon I had my shop hung round about with useful tools. I soon had my planes in order, and my work then commenced to have a finish that it had before lacked. I did not stop here, however, for I was now in my element. I was ambitious of producing much better tools than I had yet finished by the very means that I already had, made to my hands, for creating them. I hope it is understood that the result of my smelting was not common iron, but what is known as Bessemer steel. By the numerous air passages through the ore and my fan-wheel, I had been enabled to turn out the result in steel in bulk by what is called the Bessemer process, leaving the metal all ready to my hand for tools, etc. This steel was not hard enough for some purposes for which I needed it, and having forged some pieces into the proper shape, I treated them to the crucible and blast, having beforehand stamped them with a cold chisel, and finally turned out some splendid files, which was what I most needed to advance in my iron work. As a boy, I used to be expert in this case-hardening of files and steel, and my knowledge now stood me in excellent need.