Satanite Mixing and Dryout Instructions
You want to add a small amount of water to the dry mix and stir really really good for atleast 3 minutes. Then add a little more water and stir really good again, repeat this until you get a sour cream like consistency but not runny. Too much water isnt good and will cause issues. Dont mix all your material at one time, youll need to apply 2 coats with a day wait between coats to dry.
Very lightly mist the wool with water in the area you want to apply the Satanite. Use a cheap disposable paint brush to apply the Satanite, brush it on the wool no more than about 1/8" thick for the first coat. Let the first coat air dry to a hard set(approx 24hrs). Once that is done come back and apply another 1/8" thick coat and repeat the air dry as you did the with the first coat.
To Bake out:
Once both coats have air dryed to a hard set, you need to bake out the coating to give it it's structural strength.
The object of the bake out is to remove remaining moisture from the refractory. It is VERY important to remove it as slowly as possible keeping under the boiling point of water in the beginning stages of the bake out.
To do this, you will need to light your burner/s at as low a setting that they can operate safely. (There is no one size fits all setting for this since all burners operate differently).
Let it run at this low setting for up to 1 minute or until you begin to see a little steam begin whichever comes first. Repeat this step until you no longer see steam forming.
Once that has occured increase the pressure slightly, and repeat the same process as mentioned above for up to a minute or until you see steam just start begin to form whichever comes first.
Once you've reached the point that steam isn't forming and you can run the full minute, you can increase the time you run in small increments.
Repeat this process until you've reached regular operating temps.
Once you've reached operating temps you can shut down the forge and let it cool down to ambient temps. Once this is done your forge is ready to use.
I know all that seems like a lot of work and possibly overwhelming, but it is worth the time and effort to do it this way. Above all else the 3 main things to take from all that is..
1)Dont use too much water in the mix (the refractory will fail)
2) Don't try to rush the Air Curing. (Trying to use heat at this point will cause the refractory to fail)
3) Dont rush or overheat the refractory during the bake out. (Heating to fast will cause the water molecules to detach from the refractory structure too quickly causing cracks etc. Also overheating will cause steam to form within the refractory, it will expand and cause structural damage.)