Step 1
Cut the rebar into manageable sections and sort it according to diameter and straightness. Straighten bent pieces if needed.
Step 2
Place the rebar into the forge, heat it and hammer it flat to produce bar-shaped pieces that are easier to stack.
Step 3
Stack the flattened rebar with alternating layers of high carbon and stainless steel. Sprinkle Borax between the layers to act as flux and help ensure an even weld.
Step 4
Weld the stack of steel together and place in the forge. Bring the stack to a cherry red or bright red heat and maintain it for five to 10 minutes to ensure uniform heating.
Step 5
Hammer the heated stack flat. Cut it, cool it and grind off the forge residue.
Step 6
Stack the two cut pieces with borax sandwiched between and re-heat in the forge. Hammer, cool, cut and grind. Repeat the process a total of three times.
Step 7
Forge the final block of steel into a bar shape for later use or forge into the final shape.