How to Use Jigs in Blacksmithing for Consistency and Speed
In blacksmithing, there's a time for creativity—and a time for consistency. When you're forging dozens of the same item, the last thing you want is to reinvent the wheel with each hammer blow. That’s where jigs come in. These unsung heroes of the forge help streamline your workflow, reduce errors, and save a tremendous amount of time and effort.
In this post, we’ll explore what jigs are, how they’re used, and why every blacksmith—whether hobbyist or professional—should have a few in their arsenal.
What Is a Jig in Blacksmithing?
At its core, a jig is a custom-made guide or tool that helps you perform a forging task the same way every time. Jigs aren’t bought off the shelf—they’re made by you, for your specific needs. They can be as simple as a few pieces of angle iron welded together, or as complex as a multi-part assembly for creating intricate scrolls.
Jigs are typically used to:
Repeat bends or angles
Ensure consistent hole spacing or twists
Set uniform lengths for cutting
Control form while minimizing measuring
They are most useful when you're doing batch work, like forging hooks for a craft show, brackets for a railing, or components for tools. Types of Jigs You Might Use
Here are a few common jig types you can build or adapt for your forge:
1. Bending Jig
Used to create consistent curves, especially for things like curtain rods, scrollwork, or handles. You can weld curved bar stock or pipe sections to a plate and use them as a form to bend your hot metal around.
2. Twisting Jig
For decorative twists in square or round bar. A simple version includes two fixed jaws and a handle to rotate the metal evenly while hot.
3. Cut-off Jig
Used to mark or cut identical lengths of stock quickly. Mount a stop block to your workbench or anvil to eliminate repeated measuring.
4. Punch/Drift Jig
Ensures that punched holes or drifted eyelets are all placed uniformly. Helps with toolmaking or structural components.
5. Forge Welding Jig
Keeps two pieces of metal aligned during a weld, especially when precision matters, like in Damascus billets.
Why Use Jigs?
Using jigs in your forge can be a game-changer. Here's why:
Speed: No need to measure, mark, or guess every time.
Consistency: Every piece looks just like the last—critical for commissions or commercial work.
Repeatability: Perfect for batch jobs or kits that need parts to fit together.
Fatigue Reduction: Less guesswork and adjustment means more energy saved for hammering.
Professionalism: Clean, uniform results increase the perceived value of your work.
Think of jigs as tools that help your work be repeatable without being robotic—handmade, yet reliably consistent.
Real-World Example: Forging a Wall Hook
Let’s say you're making 50 wall hooks for a market. You could:
Cut each bar to length individually.
Heat each one, bend it by eye, and hope they match.
Adjust after the fact, wasting time and heat.
Or, you could:
Use a jig to quickly measure and cut each bar to the same length.
Heat and bend around a simple bending jig to form a uniform hook.
Punch a hole using a guide to keep the spacing consistent.
Suddenly, what would’ve been a 3-hour task becomes a 1-hour, high-quality batch.
Tips for Making and Using Jigs
Use scrap steel: Old angle iron, flat bar, or pipe make great jig material.
Weld securely: Your jig will take a beating. Make sure it can handle repeated hammering and heat.
Keep it simple: Over-complicated jigs often get in the way. Build only what you need.
Label them: If you make multiple jigs for different sizes or styles, mark them clearly.
Store smartly: Mount jigs on a wall or shelf near your forge for easy access.
Final Thoughts
Jigs might not be glamorous, but they’re a true sign of a thinking blacksmith—someone who values their time and strives for consistent, high-quality work. Whether you’re forging bottle openers for friends or producing hundreds of items for retail, jigs let you work faster, smarter, and with less stress.
Start simple: build a cut-off jig or a basic scroll form. You’ll wonder why you didn’t start using them sooner.
If you would like to discuss a potential project with us then do not hesitate to contact us.
