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Tuesday December 7, 2021

Making A Fullered Shoe

Written by Keith Fremlin
Category: Shoe & Tool Fabrication
Hits: 7508


ARE YOU READY??? Relax....and have fun! It's only a horseshoe.

For this tutorial, I decided to start with a shoe in blank form, made from 5/16 ths x 3/4" stock, which is center marked. It's important to determine where to start the fullering. So, here's a method that works for me.

Lay the shoe on the anvil, ground side up and heels facing you. Move the shoe away from you until you can barely see daylight between the inside toe crown of the shoe and the outside edge of the anvil table. Be sure that the shoe sits squre to the anvil! Now lay a straight edge over the shoe so that it lays parallel and flush to the edge of the table. (Image 1)

Using the straight edge as a guide, scribe the shoe with your fuller.

Are you ready???? Time to make a couple of marks! Make marks approximately 5/16ths of an inch from the outside edges, using the line scribed in Image 1. (Image 2)


Image 1


Image 2

Heat 1 Heat the branch to be fullered. Place it over the bick (horn) and bump up the ground side edge, from the mark to about 2/3rds of the branch towards the heel. (Image 3)

Here's a cross section of the branch bumped up. Notice on the photo that the upper left corner is lower than the upper right corner and the blue line shows the correct angle. (Image 4)

Now, using your fuller, mark the entire length. (Image 5)


Image 3


Image 4


Image 5

Heat 2 Heat the branch again and drive the fuller down into the stock approximately 2/3rds of the thickness of the stock; a half a bite at a time. (Image 6)

Be sure to taper out towards the end of the fullering at the heel. (Image 7)


Image 6


Image 7

Heat 3 Heat the branch to a red heat. Approximate and punch nail holes with a botton punch. (Image 8)

Forge out any frog eyes or excessive width of stock over the bick. Make another pass with the fuller lightly!

Pritchel nail holes. (Image 9)



Image 8



Image 9

Repeat the above steps on the other branch and you have a finished shoe.


Happy Fullering!


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DISCLAIMER AND WARNING: Forgery, metalsmithing, welding, blacksmithing and similar activities have INHERENT RISKS INCLUDING POTENTIAL SERIOUS INJURY TO THE PRACTITIONER AND/OR BYSTANDERS. The practitioner is responsible for ensuring adequate safety precautions (including eye protection appropriate to this type of activity) and skill, issues not covered or purported to be covered in these web pages. KEITH FREMLIN ASSUMES NO RESPONSIBILITY FOR INJURY TO THE PRACTIONER OR OTHERS ENGAGING IN ACTIVITIES OF FORGERY, METALSMITHING, WELDING, BLACKSMITHING OR THE LIKE AS ILLUSTRATED IN THESE WEB PAGES.

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