The Greenhill Forge Podcast

This week we’re talking about making holes in metal— twist bits, step bits, annular cutters, hole saws, mag drills, and plasma cutting for steel, plus the tips and techniques for smooth cutting.In this episode:Choosing twist drill bits in mild steel, including how to avoid binding or snapping bitsDifferences between high-speed steel, cobalt, and coated bits and which we prefer for shop vs. job-site workUsing cutting fluid (oil-based vs. water-based)How step bits work for enlarging holes and deburring, including practical thickness limitsUsing annular cutters (and mag drills) for larger-diameter holesHole saws for thin sheet and larger openings, including limitations on precision and thicknessThermal methods (plasma, laser, oxyacetylene) for cutting holes when drilling isn’t practicalBasic layout, punching, and other ways to keep bits from walkingAlternative approaches for oversized holes (angle grinder, chain drilling, dies, and traditional blacksmithing methods like punching or slitting and drifting)Practical notes on drill speeds/feeds and reading chip color as a temperature indicatorListener question on how to get started with alternative fuels for engines_______________________________Welcome to the Greenhill Forge Podcast, with Eric from the Greenhill Forge YouTube channel, and my buddy Amal, a fellow builder of many trades.In this podcast we’ll talk about where the real world meets experiments in alternative energy, wood heating, metal fabrication, off-grid engineering and self sufficiency, so expect discussions about workshops, tools, fabrication, building, homesteading, and what it actually takes to make those dreams real.We’ll answer a question each week, so send yours to us at https://forms.gle/zNzKTtjDnBEupLBQAWATCH the podcast on Youtube at https://www.youtube.com/@GreenhillPodLISTEN on all your favorite podcast platforms.See you next week!CHAPTERS00:00:40 Twist Drill Bits 00:03:54 Drill Bit Materials and Coatings 00:11:13 Cutting Fluid 00:15:03 Step Bits 00:22:53 Annular Cutters 00:32:40 Hole Saws 00:39:23 Plasma, Laser, and Oxyacetylene Cutting 00:43:08 Layout and Center Punching 00:44:37 Alternative Methods for Large Holes 00:51:51 Drill Speeds and Chip Color 01:00:51 Tips of the Week 01:03:32 Listener Question: Getting into Alternative Fuels

This week we’re celebrating Halloween by talking about how we’re planning on surviving the hypothetical zombie apocalypse!In this episode:Water- practical ways to store and filter itRule-of-threes survival priorities and the hardest seasonal monthsBest animals for long-term food and workCommunity and the need for specialists who produce surplus caloriesFood production and calorie-dense cropsFood preservation methods that work without electricityThe importance of saltOverlooked basicsWhat we’ll run out ofMental fortitude, physical fitness, and outdoor practice versus pure gear-based prepping_______________________________Welcome to the Greenhill Forge Podcast, with Eric from the Greenhill Forge YouTube channel, and my buddy Amal, a fellow builder of many trades.In this podcast we’ll talk about where the real world meets experiments in alternative energy, wood heating, metal fabrication, off-grid engineering and self sufficiency, so expect discussions about workshops, tools, fabrication, building, homesteading, and what it actually takes to make those dreams real.We’ll answer a question each week, so send yours to us at https://forms.gle/zNzKTtjDnBEupLBQAWATCH the podcast on Youtube at https://www.youtube.com/@GreenhillPodLISTEN on all your favorite podcast platforms.See you next week!CHAPTERS00:02:49 Water and the rule of threes00:05:32 Realistic collapse scenarios00:08:10 Surviving the first two years and lean months00:09:23 Water storage and filtration00:15:03 Food storage, cooking, and fuel00:18:40 Animals for food and work00:19:55 Community size and specialization00:22:24 Potatoes, grains, and calorie density00:22:54 Seed saving and heirloom varieties00:29:14 Fertilizers, companion planting, and composting00:30:55 Dentistry and health realities00:31:38 Food preservation methods00:36:57 Salt as a critical resource00:38:58 Clothing, shoes, and textiles00:46:08 Soap, toilet paper, cordage, and tools00:49:42 Prepping strategies and location00:55:34 Communication without modern infrastructure00:58:45 Mental fortitude and physical fitness01:12:22 Tips of the Week

This week we’re talking about Eric’s recent video on his absorption refrigerator design that uses water as the refrigerant and calcium chloride (road salt) to absorb the vapor, powered by heat instead of a compressor. We’re going through how the cycle works, the main components, the practical limits, and what it takes to keep the system running.Full Youtube video on fire-powered refrigeration: https://youtu.be/3sv7TBtHcgo?si=qB2NBwEFFEgI2xlkIn this episode:How an absorption refrigerator cycles water as the refrigerant with calcium chloride as the absorbentWhy calcium chloride is used instead of regular salt or other common absorbents like lithium bromideThe roles of the generator, absorber, condenser, expansion valve, and evaporatorHow vacuum lowers the boiling point to produce cooling and why the system stays below ambient pressureTemperature limits of water as a refrigerant and why making ice is difficultHow the U-bend and pressure differences create directional flow without a compressorPractical considerations for off-grid use, including supplementing a root cellar and managing heat inputPower needs for pumps and fans, and options for using solar heat on the generatorChallenges with scaling evaporators, absorber capacity, and monitoring pressures and temperaturesStructural and vacuum-related details that affect building and operating the system_______________________________Welcome to the Greenhill Forge Podcast, with Eric from the Greenhill Forge YouTube channel, and my buddy Amal, a fellow builder of many trades.In this podcast we’ll talk about where the real world meets experiments in alternative energy, wood heating, metal fabrication, off-grid engineering and self sufficiency, so expect discussions about workshops, tools, fabrication, building, homesteading, and what it actually takes to make those dreams real.We’ll answer a question each week, so send yours to us at https://forms.gle/zNzKTtjDnBEupLBQAWATCH the podcast on Youtube at https://www.youtube.com/@GreenhillPodLISTEN on all your favorite podcast platforms.See you next week!_______________________________CHAPTERS00:00:04 Absorption refrigerator design overview00:01:05 Importance of cooling and off-grid power sources00:02:36 Choosing water and calcium chloride over other options00:03:05 How calcium chloride absorbs water vapor in a closed system00:05:26 Exothermic reaction when calcium chloride hydrates00:06:30 Calcium chloride as road salt and a concrete accelerator00:07:47 Water as the refrigerant and the absorber’s role00:08:08 Cooling the absorber to maintain absorption capacity00:09:26 Multiple heat cycles compared with vapor compression00:10:23 Expansion valve, pressure drop, and one-time coolers00:11:48 Generator and absorber replacing the compressor00:13:09 Lifting refrigerant with heat and gravity feed00:13:41 Water’s heat capacity advantages and drawbacks as a refrigerant00:14:08 Latent heat and phase change explained00:15:46 Boiling point changes with pressure and elevation00:16:54 Using vacuum to lower the boiling point for cooling00:17:58 Freezing limitations of water as a refrigerant00:19:03 Using the system to supplement a root cellar00:19:43 Achievable evaporator temperatures and ice-making challenges00:20:24 Issues with antifreeze additives in the system00:21:47 Flow through the condenser, needle valve, and evaporator00:22:05 U-bend as a check valve and pressure separation00:22:57 Running the generator leg with the valve closed00:24:18 Split of flow between the evaporator and recirculation00:27:34 Design process and differences from industrial systems00:28:00 Sizing the U-bend for the pressure differential00:29:07 Ambient temperature effects on evaporator performance00:30:35 Enclosing the evaporator and accounting for fan heat00:31:45 Adding evaporators in parallel and absorber capacity00:33:29 Limited published data on calcium chloride as an absorbent00:36:22 Off-grid challenges with compressors and mechanical energy00:37:13 Power draw and solar options for heat and pumps00:39:00 Solar heating the generator and thermal storage ideas00:41:11 Solar irradiance and concentrating sunlight00:42:45 Solar panel efficiency versus direct heat collection00:43:30 Using solar-heated fluid to drive the generator00:44:37 Potential cooling capacity for small units00:45:57 Sensors, Arduino modules, and voltage readings00:48:26 Pressure sensors, absolute versus gauge pressure00:50:07 System pressures remaining below ambient00:51:15 Structural deflection and reinforcement under vacuum00:52:58 Vacuum distillation and related applications00:56:35 Water level shifts between generator and absorber01:00:06 Water column acting as a barometer

This week we’re talking about alternative alternative energy — ways to run engines and produce power that aren’t the usual solar panels or wind turbines. We go through waste vegetable oil and biodiesel, wood gasification, small-scale ethanol, methane digesters, and a few mechanical systems like wind pumps, water wheels, trompes, and Stirling engines._______________________________Welcome to the Greenhill Forge Podcast, with Eric from the Greenhill Forge YouTube channel, and my buddy Amal, a fellow builder of many trades.In this podcast we’ll talk about where the real world meets experiments in alternative energy, wood heating, metal fabrication, off-grid engineering and self sufficiency, so expect discussions about workshops, tools, fabrication, building, homesteading, and what it actually takes to make those dreams real.We’ll answer a question each week, so send yours to us at https://forms.gle/zNzKTtjDnBEupLBQAWATCH the podcast on Youtube at https://www.youtube.com/@GreenhillPodLISTEN on all your favorite podcast platforms.See you next week!_______________________________CHAPTERS00:00:14 Overview of alternative fuels and mechanical energy systems00:00:58 Running older diesel engines on waste vegetable oil00:02:02 Cleaning and filtering waste vegetable oil00:03:30 Dual-tank veggie oil conversion with preheating and purging00:05:07 Making biodiesel from waste oil00:06:35 Sourcing methanol and its cost for biodiesel00:07:50 Biodiesel compatibility with modern engines and seals00:09:04 Mixing vegetable oil with diesel or kerosene as a simpler option00:13:31 Using multi-fuel generators and military equipment on alternative fuels00:16:41 Filtering methods and removing water from waste oil00:19:04 Trade-offs between pre-processing fuel and engine complexity00:23:54 Rebuildable injectors and choosing older mechanical diesel engines00:27:00 Running tractors and farm equipment on vegetable oil00:29:25 Do indirect injection diesels handle biofuels better than direct injection00:31:00 Availability of waste vegetable oil00:33:46 Wood gasification and producing syngas for gasoline engines00:35:56 Small-scale ethanol production from sugar or starch crops00:37:02 Fermentation, distillation process, and energy input vs output00:40:34 Using solar heat to reduce energy needed for distillation00:44:00 Dehydrating ethanol with molecular sieves for fuel use00:46:57 Separating methanol heads and monitoring distillation temperatures00:50:41 Ethanol yields per acre and the role of farm subsidies00:53:35 Methane digesters that turn farm waste into burnable gas00:56:20 Mixing manure, scraps, and fat as digester feedstock00:57:45 Batch versus continuous digester systems for daily use01:02:38 Mechanical windmills and water wheels for pumping and workshop power01:05:07 Using water wheels to grind grain or run equipment01:06:48 Trompes that use falling water to create low-pressure compressed air for forges01:10:05 Stirling engines that run on heat differentials01:13:55 Listener Question: Advice for starting out today01:17:25 Tips of the Week: Trade school and trying new things

This week we're talking wood stoves. We've both heated with wood for decades, so this is the stuff we actually weigh when we're buying and using them._______________________________Welcome to the Greenhill Forge Podcast, with Eric from the Greenhill Forge YouTube channel, and my buddy Amal, a fellow builder of many trades.In this podcast we’ll talk about where the real world meets experiments in alternative energy, wood heating, metal fabrication, off-grid engineering and self sufficiency, so expect discussions about workshops, tools, fabrication, building, homesteading, and what it actually takes to make those dreams real.We’ll answer a question each week, so send yours to us at https://forms.gle/zNzKTtjDnBEupLBQAIn this episode:How to choose a wood stove for your houseHow to size a wood stove to square footage and insulationOversized versus undersized stoves, and why running one too cool causes creosoteHow long to season firewood, how much wood a winter takes, and where to get itPrimary heat versus an occasional fireSecondary-burn stoves versus catalytic stovesSteel versus cast iron versus soapstoneWhat to check on a used stove, and what a new one costsOutside-air kits, indoor smoke, and carbon monoxide safetyClearances and getting a stove installed safelyListener question: How did you acquire your skills and knowledge?Weekly shop tips and tricksCreosote powder: US: https://link.amazon/B0iKW8VfJ ; UK: https://shop.vitcas.com/cfc-chimney-flue-cleaner.htmlWATCH the podcast on Youtube at https://www.youtube.com/@GreenhillPodLISTEN on all your favorite podcast platforms.See you next week!-----------------CHAPTERS00:00:00 Seasoned wood, and staying ahead of a two-year supply00:04:40 Sizing the wood stove to the house: stove size versus square footage and insulation00:05:15 Oversized stoves, smoldering, and creosote00:06:08 House insulation matters00:07:43 Creosote, chimney fires, and smoke exposure00:10:15 Sizing rule of thumb00:11:51 Heat distribution: fans, ducting, basement furnaces, radiant floors00:18:37 Primary heat versus occasional use00:20:01 Wood use per winter, before and after insulation00:21:16 Sourcing rounds and chips from tree crews00:23:17 Single burn, secondary reburn, and catalytic stoves00:25:01 EPA testing00:28:24 Intake controls, exhaust dampers, and shutting a stove down00:31:19 Carbon monoxide00:32:08 How catalytic converters work, and the bypass00:37:50 Fuel quality and catalytic lifespan00:39:16 Hybrid stoves and short chimneys00:42:53 A flue-mounted catalytic retrofit00:47:18 After-stove modifications, heat exchangers, and insurance00:49:15 Steel, cast iron, and soapstone00:54:14 Repairing cracked cast iron00:55:54 Thin sheet-metal stoves00:56:51 Stove brands, regulation, and burn bans01:10:05 Outside-air kits and indoor particulates01:13:54 Listener question: How did you acquire your skills and knowledge?01:18:52 Weekly tip: shop mice!

This week we’re talking about bike-powered machinery. No fabrication or welding required, tho you may find it useful.Appropedia https://www.appropedia.org/Welcome_to_AppropediaPrevention and Control of Distortion in Arc Welding (1945) https://www.youtube.com/watch?v=yhyekAvFc68In this episode:A practical guide to turning a yard-sale bike into a power takeoff, built around an upcoming wheat thresherHow much power you can expect andWhere to begin the design processGearing, freewheels, flip-flop hubs, steel frames, and how to tension a chain that is never perfectly roundBelt drive with inner tubes versus chain, including the old chicken rotisserie as a gear-reduction exampleStanding the bike up, bike trainers, a sideways shaft, adult trikes, and the simple option of chaining straight off the front ringMulti-person setups, Appropedia, and why twenty people still only add up to a few kilowattsWhy direct mechanical drive beats pedaling into a battery, and the kosher thresher they built years agoA listener question on eco-friendly building materials, plus a shop note on weld order and distortion_______________________________Welcome to the Greenhill Forge Podcast, with Eric from the Greenhill Forge YouTube channel, and my buddy Amal, a fellow builder of many trades.In this podcast we’ll talk about where the real world meets experiments in alternative energy, wood heating, metal fabrication, off-grid engineering and self sufficiency, so expect discussions about workshops, tools, fabrication, building, homesteading, and what it actually takes to make those dreams real.We’ll answer a question each week, so send yours to us at https://forms.gle/zNzKTtjDnBEupLBQAWATCH the podcast on Youtube at https://www.youtube.com/@GreenhillPodLISTEN on all your favorite podcast platforms.See you next week!_______________________________CHAPTERS0:00 Bicycle-powered equipment and the wheat thresher build0:51 How many watts a person can actually put out2:07 Start at the implement and work backward3:24 Power takeoff: rear wheel or straight off the crank4:29 Keeping the bike’s gears, freewheel vs cassette9:46 Flip-flop hubs and a final-drive ring on the other side11:43 Steel frame over aluminum13:01 Derailleurs, horizontal dropouts, and chain tension15:28 Belt drive: rim as a pulley, inner tubes as belts18:38 Gear ratios and the chicken rotisserie25:00 Chain tensioners and which side of the chain is loaded27:32 Geared one-way drive vs fixed forward-and-back31:46 Sideways shaft takeoff34:14 Adult trikes as a ready-made shaft37:09 Standing the bike up and locking the steering40:24 Bike trainers as a stand and power takeoff44:18 Simplest path: chain straight off the front chainring46:13 Safety with chains and chainrings47:07 Multi-person power and shared shafts52:39 Appropedia and scaling human power57:25 Mechanical drive vs electricity, and why solar changes the math58:58 The kosher wheat thresher1:02:43 Recap of the practical options1:04:19 Flywheels, a pedal bench grinder, and line-shaft shops1:07:10 Listener question: eco-friendly vs conventional building materials1:17:37 Tips and tricks: weld order and distortion

This week we’re talking about building for longevity — what actually makes a house last 20 years versus 500. We compare modern American stick framing, European masonry, traditional stone, and natural building methods like cob, rammed earth, and straw bale, and why water, airtightness, climate, and skill matter more than the material itself.In this episode:Why old buildings are still standing and modern ones often aren’tHow American stick framing works, and how it has changedTight houses, moisture, mold, and the “Ziploc bag” problemHRVs, wood stoves, negative pressure, and indoor air qualityRain screens vs older tar-paper-and-siding assembliesRepairability vs 25-year wall warrantiesSpeed, year-round building, and the trades skills gapWhy buildings fail as systems, not as single productsModern European masonry and brick-as-rainscreen constructionDry-in time, cost, and US vs UK laborBrick veneer problems, window upgrades, and out-of-plumb stone wallsMaintenance: masonry vs wood sidingLong-lasting roofs: slate, clay tile, and standing seamTraditional stone, field stone, and lost mason knowledgeLaying stone on its natural bed, and orienting wood the way it grewNatural building / “hippie building”: cob, rammed earth, straw bale, earthships, earthbags, and papercreteThermal mass, overhangs, drainage, and climate-specific designPermitting, insurance, and hybrid buildsQuestion of the week: the tool you most regret buyingTip of the week: spend money on tools that need to be precise_______________________________Welcome to the Greenhill Forge Podcast, with Eric from the Greenhill Forge YouTube channel, and my buddy Amal, a fellow builder of many trades.In this podcast we’ll talk about where the real world meets experiments in alternative energy, wood heating, metal fabrication, off-grid engineering and self sufficiency, so expect discussions about workshops, tools, fabrication, building, homesteading, and what it actually takes to make those dreams real.We’ll answer a question each week, so send yours to us at https://forms.gle/zNzKTtjDnBEupLBQAWATCH the podcast on Youtube at https://www.youtube.com/@GreenhillPodLISTEN on all your favorite podcast platforms.See you next week!_______________________________CHAPTERS00:00:00 Intro: Building for longevity00:02:22 Modern American stick framing00:05:16 Tight houses, moisture, and the “Ziploc bag” problem00:11:04 Wood stoves, negative pressure, and indoor air00:14:38 Rain screens: how wall assemblies actually last00:19:16 25-year warranties vs easy repairs00:22:19 Speed, seasons, and the skills gap00:24:06 Buildings are systems, not products00:25:33 Modern European masonry00:27:01 Dry-in time, cost, and labor00:31:26 Brick veneer, repairs, and out-of-plumb walls00:37:01 Low maintenance vs hard to get right00:42:11 Roofs that last: slate, clay, and standing seam00:49:19 Traditional stone, field stone, and lost knowledge00:52:32 Natural bed, grain, and why orientation matters00:55:34 Hippie building00:56:56 Cob: Devon tradition vs modern cob01:00:42 Climate, skill, and how natural building fails01:05:03 Good feet, good hats, and keeping water off01:06:16 Thermal mass: desert gift, cold-climate problem01:08:49 Rammed earth01:14:22 Straw bale, earthships, earthbags, and papercrete01:18:16 You will never build a perfectly watertight house01:19:42 Permits, insurance, and hybrid builds01:23:10 Question of the week: the tool you most regret buying01:28:47 Tip of the week

This week we’re comparing the small machines that actually get used on homesteads, hobby farms and small properties: compact tractors, skid steers, walk-behind tractors and mini excavators.We’ll go through the real jobs — clearing, grading, digging, gardens, compost, firewood, moving material — plus what to rent vs buy, implement cost and swap time, PTO vs hydraulics, fuel, maintenance, where these things get tippy or annoying, and what we’d buy first if we could only afford one.In this episode:Which machines are usually rented vs purchasedCompact tractor (about 25-40 hp) as the most practical first machineMini excavator as the strongest second machine for digging and tight garden workWhy mini skid steers / dingos rarely earn their keep on a homesteadSkid steer strengths (lift, attachments, speed) and weaknesses (price, fuel, visibility)Walk-behind tractors for small-scale market gardeningImplement storage, used market and DIY buildsDealer vs cheap import, plus the US sub-25 hp emissions cutoffListener question: starting weldingTips of the weekCHAPTERS00:00 - Intro: best small machinery for homesteads, hobby farms and smallholdings00:51 - Start with the job: raw land vs established property01:26 - Heavy clearing and big root balls. Rent, don’t buy04:46 - After infrastructure: when owning a machine starts to make sense09:51 - Compact tractors, skid steers, walk-behind tractors and mini excavators11:00 - Mini skid steers / dingos: great on job sites, poor homestead fit13:55 - Tipping and stability (mini skids, then tractors)14:13 - Compact tractors: Swiss Army knife, balance problems, counterweights19:01 - Walk-behind tractors: cheap entry, high labour, fast implement changes21:34 - Mini excavators: digging, gardens, drainage, compost, reach vs travel speed33:01 - Skid steers: power, attachments, fuel, visibility, implement swap speed35:07 - Tractor vs skid steer: pulling, road legality, cost, fuel, maintenance43:53 - How implements are powered: PTO vs hydraulics45:39 - Maintenance, parts and how hard each machine is to work on48:45 - Buying strategy if you can only afford one machine first52:51 - Size, emissions (sub-25 hp) and dealer vs import brands55:45 - Audience question: how to start welding01:00:51 - Weekly tips: stop procrastinating simple jobs + make test pieces01:04:37 - Wrap-up_______________________________Welcome to the Greenhill Forge Podcast, with Eric from the Greenhill Forge YouTube channel, and my buddy Amal, a fellow builder of many trades.In this podcast we’ll talk about where the real world meets experiments in alternative energy, wood heating, metal fabrication, off-grid engineering and self sufficiency, so expect discussions about workshops, tools, fabrication, building, homesteading, and what it actually takes to make those dreams real.We’ll answer a question each week, so send yours to us at https://forms.gle/zNzKTtjDnBEupLBQAWATCH the podcast on Youtube at https://www.youtube.com/@GreenhillPodLISTEN on all your favorite podcast platforms.See you next week!

This week we’re talking about the most valuable skills that we've learned along the way, and we answer a listener question about buying tools as a beginner._______________________________Welcome to the Greenhill Forge Podcast, with Eric from the Greenhill Forge YouTube channel, and my buddy Amal, a fellow builder of many trades.In this podcast we’ll talk about where the real world meets experiments in alternative energy, wood heating, metal fabrication, off-grid engineering and self sufficiency, so expect discussions about workshops, tools, fabrication, building, homesteading, and what it actually takes to make those dreams real.We’ll answer a question each week, so send yours to us at https://forms.gle/zNzKTtjDnBEupLBQAWATCH the podcast on Youtube at https://www.youtube.com/@GreenhillPodLISTEN on all your favorite podcast platforms.See you next week!

Welcome to the Greenhill Forge Podcast, with Eric from the Greenhill Forge YouTube channel, and my buddy Amal, a fellow builder of many trades.In this podcast we’ll talk about where the real world meets experiments in alternative energy, wood heating, metal fabrication, off-grid engineering and self sufficiency, so expect discussions about workshops, tools, fabrication, building, homesteading, and what it actually takes to make those dreams real.This week we’re covering our favorite metal shop tools and answering a listener question about insulating old stone buildings.We’ll answer a question each week, so send yours to us at https://forms.gle/zNzKTtjDnBEupLBQAWATCH the podcast on Youtube at https://www.youtube.com/@GreenhillPodLISTEN on all your favorite podcast platforms.See you next Friday!