Railroad Track Anvil

A section of railroad rail is a common starting point for blacksmiths, farriers, and metalworkers seeking a durable, inexpensive striking surface. A railroad track anvil is not just a piece of scrap metal; it is a highly functional tool forged from steel designed to withstand immense pressure and wear. Understanding the properties of the rail itself and how to shape it effectively is key to creating a useful and long-lasting anvil. This guide details the specifications of different rail types used for anvils and explores how to modify and use them for various metalworking tasks.

Railroad Track Anvil Specifications

The primary characteristic defining a piece of railroad rail is its weight per unit length, typically measured in pounds per yard (lb/yd). This weight directly correlates to the rail’s cross-sectional dimensions, including the height, base width, and head size. Heavier rails provide more mass, which is crucial for an effective anvil. Greater mass under the hammer blow means more of the energy is transferred into the workpiece rather than being absorbed by the anvil or causing it to bounce.

When selecting a piece of rail for a railroad track anvil, the weight is a key specification to consider. Common rail weights you might encounter include:

• ASCE 40 (40 lb/yd): A lighter rail, often found on old mining tracks or light industrial lines. While usable, its small mass makes it less ideal for heavy forging.
• ASCE 60 (60 lb/yd): A more substantial option, providing enough mass for general blacksmithing and knife making. This is a common and accessible size.
• ASCE 85 (85 lb/yd): A heavy and desirable rail size. The larger head and web provide significant mass and a wider working face.
• AREMA 115 (115 lb/yd): Mainline track rail that offers excellent mass and a large surface area. These make for very stable and effective anvils.
• AREMA 136/141 (136-141 lb/yd): The heaviest class of rail used on major freight lines. A railroad track anvil made from this stock is a top-tier option, providing maximum mass and stability.

The metallurgical composition of the rail is another critical part of its specifications. Railroad rails are made from high-carbon steel, with specific percentages of manganese and silicon to increase strength, hardness, and abrasion resistance. A typical composition includes 0.67% to 0.82% carbon and 0.7% to 1% manganese for heavier rails. This composition results in a very tough and durable material that, while not as hard as a modern forged steel anvil face, is more than sufficient for most forging operations.

Railroad Track Anvil Specifications Table

This table provides a general overview of the dimensions associated with common rail profiles, helping you understand the railroad track anvil specifications you might acquire.

Note: Dimensions are approximate and can vary slightly by manufacturer and wear.

The best length for a railroad track anvil is subjective, but a section of 18 to 24 inches provides a good balance of mass and working surface without being too cumbersome.

Creating and Shaping Your Railroad Track Anvil

A raw piece of railroad track is functional, but modifying it can greatly enhance its versatility. The goal of shaping is to create features found on traditional anvils, such as a horn, a hardy hole, and a flat, smooth face.

1. Cutting and Shaping the Horn:
   The most common modification is to shape one end of the rail into a horn. This is used for bending, drawing out material, and forming curves. The horn is typically created by cutting away material from the web and base of the rail, leaving the head to be ground into a conical or rounded point. This can be done with an oxy-acetylene torch, a plasma cutter, or an angle grinder with cutting discs.

When shaping the horn, it’s often best to leave a substantial amount of the web intact directly under the head to provide support. Some makers weld additional material underneath the horn to create a truer conical shape and add mass. Grinding the horn smooth is essential to avoid leaving marks on the workpiece.

2. Flattening the Face:
   The top surface of the rail head serves as the anvil’s face. Used rails often have a worn, rounded, or uneven surface. While some rounding can be useful, a flat, level face is necessary for precision work. You can flatten the face using a 7-inch angle grinder and a straight edge, like a framing square. Mark high spots with a felt-tip marker and grind them down until the face is level. For a perfectly flat surface, a machine shop can mill the face, but this is often unnecessary for general work.
3. Adding a Hardy Hole:
   A hardy hole is a square hole in the anvil face used to hold various tools, known as hardy tools (e.g., cutters, fullers, swages). Adding one to a railroad track anvil significantly increases its functionality. To create a hardy hole:

• Lay out the square hole (e.g., 3/4″ or 1″).
• Drill a series of small holes at the corners and a larger hole in the center.
• Use files or a drift to clean out the remaining material and form the square shape.
• Alternatively, drill a large round hole and weld a piece of square tubing into it to create the finished hardy hole.

The steel in the rail is very tough, so drilling can be challenging. Use high-quality drill bits, cutting fluid, and a slow, steady speed.

Different Parts of the Anvil

A well-designed railroad track anvil offers multiple working surfaces, and its utility is not limited to the top face.

• Vertical Orientation: For maximum efficiency, orient the anvil vertically so the hammer strikes directly above the main body of the rail. Standing a 20-inch section on its end and using the cross-section of the head as the striking surface puts the entire mass of the anvil directly under the blow. This is the most effective way to use the tool for heavy drawing-out operations, as it minimizes energy loss and maximizes rebound.
• Horizontal Face: The traditional orientation, with the rail lying on its base, provides a long, flat surface for general forging, flattening, and planishing. The horn is accessible for bending and shaping.
• The Base: The bottom of the rail base can be used as a wider, flatter surface. When turned upside down, the base provides a large, stable area for straightening long pieces of stock.
• The Web and Fillets: The curved transitions (fillets) between the head and the web, and the web and the base, can be used as built-in swages. These curves are perfect for rounding edges, fullering, or shaping cylindrical stock. By simply rotating the anvil, you can access multiple radii for different applications.

Securing the railroad track anvil is critical for both safety and performance. A light anvil will move or “walk” with each hammer blow, which is inefficient and dangerous. It should be fastened securely to a heavy, stable base, such as a large tree stump or a fabricated steel stand. Notches can be ground into the anvil’s base to accommodate spikes or bolts, preventing any lateral movement.