Forging Carbon Steel Pans: A Guide

Forging a carbon steel pan is a lucrative skill to have and can be done within a few minutes. The process involves heating a circular steel plate in a forge until it becomes malleable, then beating it into shape using a local mould and a hammer. The sides of the plate are shaped with a slant, and a handle is added, usually made from steel or wood. The pan is then ground with a grinder to smoothen the surface, creating a rustic, hand-forged finish. Carbon steel pans are superior to cast iron as they are less porous, season quicker, and are more tolerant of higher temperatures. They are also lighter and have sloped sides, making them ideal for tossing foods and sautéing.

Sourcing a circular steel plate

When selecting a steel plate, it's also important to consider the application. For instance, if you're forging a pan for personal use, you might opt for a thinner plate, whereas if you're creating a pan for industrial use, you'll need a thicker, more durable plate. Additionally, the grade of steel you choose will impact the performance, especially in industries like aerospace, where weight and strength are crucial.

Another factor to keep in mind is the material composition of the steel plate. Alloying elements such as carbon, manganese, and chromium can be adjusted to enhance specific properties. For instance, you may want to increase chromium in the alloy to improve corrosion resistance, which is particularly important if your pan will be exposed to moisture and humidity.

Before purchasing your circular steel plate, ensure that it meets the required specifications and is suitable for your intended use. Once you've sourced your steel plate, you can move on to the next steps of the forging process, including heating, shaping, and finishing your carbon steel pan.

Heating and shaping the plate

Firstly, get a large circular steel plate, as the size of your skillet will depend on the size of the plate. Place this plate in a forge to heat it up. The forge will make the plate malleable, and you want it to be very hot so that it is easy to shape when you start hammering it.

Now, it's time to beat the plate into the desired shape. You will need a local mold for this step, preferably with a deep surface. This mold can be made of wood or metal. Take the plate out of the forge and place it on the mold. Use a hammer to beat the plate, following the shape of the mold, until you achieve an inwardly curved shape. Remember to put the plate back in the forge frequently to keep it hot and malleable.

Next, you will shape the sides of the plate with your hammer. Slant the sides instead of making them straight and ensure the bottom is flat. Keep the steel plate hot by heating it in the forge at regular intervals. You can use a handy grinder or sandpaper to smoothen the surface and bottom of the plate.

At this stage, your carbon steel pan is almost ready! All that's left is to add the handle. Make sure the handle is made of steel and is not too heavy, so it balances with the weight of the pan. Heat the handle in the forge and beat it with a hammer to flatten it. Drill holes in the handle and the pan, ensuring they align, and join them together using screws or other fasteners.

Finally, you can further smoothen and polish your carbon steel pan. Grind it with a grinder or sandpaper to improve its heat conduction. You can also apply a mixture of beeswax and coconut oil to create a dark patina and prevent rust.

Adding a handle

Firstly, select an appropriate metal for the handle. While it should be made of steel, ensure that it is a metal that doesn't get hot easily, as you will be holding it while cooking. Heat the handle in a forge until it becomes malleable. Take the heated handle and beat it with a hammer to flatten it into a long strip. You can also roll it out with a rolling pin to achieve the desired shape. Ensure that the handle does not become too heavy, as it needs to balance with the weight of the pan.

Next, you will need to attach the handle to the pan. To do this, drill a hole in the pan where the handle will be attached. Drill a corresponding hole in the flattened part of the handle, ensuring that the holes align. You can then join the handle to the pan by riveting it or using a screw or any other suitable fastening method.

Once the handle is attached, you can finish the process by polishing the pan. Use a wire brush or sandpaper to smoothen the surface and remove any imperfections. Remember to wear safety gear, including gloves and eye protection, during this process.

Grinding and smoothing the pan

Firstly, you will need to use a grinder to smoothen the surface of the pan. This step is important as it removes any roughness and creates an even finish. You can use a handheld grinder or sandpaper for this process. Grinding will also enhance the heat conduction of the carbon steel. Be sure to wear safety gear, including eye protection, during this step to protect yourself from any debris or sparks.

When grinding, use smooth, even strokes and apply light pressure to the grinder. You want to avoid creating any deep scratches or grooves on the surface. Take your time with this step, as a thorough grinding job will pay off in the long run. Pay extra attention to the cooking surface and ensure it is smooth and free of any imperfections.

Once you are satisfied with the grinding, the next step is to remove any remaining forge scale and clean the pan thoroughly. This can be done by soaking the pan in vinegar for several days. The vinegar will help to dissolve any remaining impurities and leave the pan with a clean, smooth surface. After soaking, use a wire brush to remove any remaining residue.

The next step is to heat the pan in an oven at 500 degrees Fahrenheit for about an hour. This step serves multiple purposes. Firstly, it will evaporate any remaining moisture from the vinegar soaking process. Secondly, it will create a surface oxidation that helps to prevent rust. Finally, it will turn the pan a nice dark blue colour.

Once the pan has cooled down, it's time to apply a protective coating. For this, you can use a mixture of beeswax and coconut oil. Rub this mixture all over the pan while it is still warm. This will help to season the pan and create a natural non-stick surface. Over time, as you use the pan, it will develop a dark patina, enhancing its non-stick properties.

And there you have it! A smoothly ground and seasoned carbon steel pan, ready for many years of cooking enjoyment. Just be sure to follow the care instructions for carbon steel pans to ensure your pan stays in top condition.

Seasoning the pan

Seasoning a carbon steel pan is a straightforward process that will help protect the pan from corrosion and rust and create a non-stick surface. Here is a step-by-step guide to seasoning your carbon steel pan:

Step 1: Remove the Protective Coating

Carbon steel pans often come with a protective coating, such as beeswax, to prevent rusting. This layer needs to be removed before seasoning. Use hot water, dish soap, and a sponge or bristle brush to scrub off the coating. Some manufacturers may have specific instructions for removing the coating, so be sure to check the instructions that come with your pan.

Step 2: Dry the Pan

Once the protective coating is removed, dry the pan thoroughly with a towel. It is important to remove any moisture as water can cause rusting. You can also place the pan on a stovetop burner for a few minutes to ensure all moisture is evaporated.

Step 3: Heat the Pan

Heating the pan helps open up the pores and prepares the surface for seasoning. Place the pan on the stovetop over medium heat for 5-10 minutes. If using an oven method, preheat the oven to 475-500°F (240-260°C) and place the pan in the oven for 2-3 minutes.

Step 4: Apply Oil

Choose a neutral oil with a high smoke point, such as canola oil, vegetable oil, grapeseed oil, avocado oil, or sunflower oil. Avoid using oils with low smoke points, such as butter or olive oil. Using a paper towel or kitchen rag, rub a very small amount of oil onto the inside and outside of the pan. Ensure that the pan is coated thinly and evenly, and buff away any excess oil until the pan looks dry.

Step 5: Heat the Pan Again

Place the oiled pan back on the stovetop over medium to medium-high heat. If using the oven method, place the pan upside down on the center rack of the preheated oven. Heat the pan until the oil starts to smoke, which indicates that the oil has reached its smoke point and is forming a polymer coating on the pan. The pan will smoke heavily during this process, so ensure your kitchen is well-ventilated.

Step 6: Cool and Wipe the Pan

Once the pan has smoked for a few minutes, turn off the heat and allow it to cool down. If using the oven method, turn off the oven and let the pan cool completely inside. Once cool, wipe down the pan with a paper towel to remove any excess oil.

Step 7: Repeat as Needed

Your pan is now seasoned and ready to use! If desired, you can repeat the oil application and heating process to build up additional layers of seasoning. With each use of the pan, the seasoning will continue to develop and improve.

Remember, seasoning a carbon steel pan is a simple and effective way to protect your cookware and enhance its performance. By following these steps, you'll be able to create a natural non-stick surface that is perfect for cooking a variety of dishes.

Frequently asked questions