Augustus F. Rose

“ If, in this piece of work, it is desired to make the surface a little more interesting, it may be done by taking any hammer with a smooth domed face and going over the surface. This, however, should be done before sawing. As the hammering stretches the metal somewhat, if it is left till after the sawing is done, it means more filing to get the design into shape. For a beginning this exercise has proved very satisfactory, as it gives the pupil an acquaintance with the metal and uses but a small piece of material. ”

“ Repousse or embossing involves practically the same principle as modeling in clay or wax, the only difference being that metal is used as the material and that different tools are employed. In this, as in clay or wax work, it is desirable to bring certain parts of a design into relief; to do this with metal the work must be placed on a substance which will give some resistance and yet allow each blow of the hammer or tool to make an impression. The substance commonly used for this purpose has the following composition, in the proportions given:
Black pitch 1 lb. ”

“ To insure this the joint is scraped bright with some sharpe-edged tool. Care must be taken to keep the fingers away from the joint as any moisture or greasy substance will prevent the solder from running. The best results are obtained only by being extremely careful as to cleanliness throughout the process. Being sure that the slab is perfectly clean, a little water is put in it and the lump of borax is ground around until the water becomes like thin cream. If powdered borax is used a block of wood will answer as a pestle to grind the borax to the right consistency. ”

“ For most of the work from 18 to 24 gauge is used, while metal from 12 to 18 gauge is used occasionally.
Copper wire is used in several sizes for making rivets.
No. 22 and 28 iron wire is indispensable for binding when soldering.
Easy running silver solder may be made by the user, but as a small piece will solder many joints, and as it is not practical to make it in small quantities, it is better to buy it ready made as desired.
Powdered or lump borax is used as a flux in soldering. Charcoal or asbestos blocks are used when soldering small work. ”

“ The equipment necessary for a start in Copper work need cost but little if the teacher is somewhat ingenious, for the patterns of the various anvils may be made by him; from these patterns the castings can be made at any foundry for three or four cents per pound. It is better to begin with a few anvils and tools and to add one or two at a time as the need is felt for a more varied supply. If the work can be done in a room already fitted with benches and vises, it will reduce the first cost considerably. Any home-made bench will do if a regulation one is not to be had. ”

“ Wood and iron were the first materials used and are yet indispensable, but experience has led those who are developing this work to believe that there are other materials as well adapted to Manual Training work in all its various forms. Clay, used not only for modeling but for ceramic work as well, leather, brass and copper are materials that have also been put to the test and found satisfactory in many ways. ”

“ A bar must be made for the top, wide enough for the ribbon to be passed through and fastened. This bar is made by cutting a slot in a piece of metal of the same gauge as the pendant, or by bending a piece of wire around a piece of metal about 1/16 of an inch thick and the width of the ribbon, making the ends meet in the centre of one of the long sides. If more than one of these pieces is needed, the wire is wound around the metal as many times as there are pieces required and sawed apart. ”

“ Take a piece of iron or steel A, Plate 50, thicker than the desired length of the rivet and drill a hole through it having its diameter a little greater than the wire of the rivet. Take a piece of copper wire of the required diameter and about 1/8" longer than the thickness of the iron. Place the wire in the hole and the iron on some smooth metal surface, B. With a hammer make a burr of the wire that projects above the iron. ”

“ When the design has been pierced or embossed, the laps can be bent over a piece of metal equal in thickness to that of the pad. If the design is to be carried out in enamel, all bending must be done before enameling as any expansion or contraction of the metal will crack the enamel. ”

“ Invert bowl and handle and lay them upon a level block of charcoal, as shown at Figure 28. Four or five wire nails or pieces of iron wire forced into the charcoal keep the handle and bowl together. The borax is applied and sufficient solder to make a good joint. Use no more solder than is necessary, as it will have to be removed by filing and the less filing that is done about such a joint the better the work will be. After the exercise has cooled, it may be pickled, washed and dried. ”

“ The pupil conceives the idea and makes several sketches of it, carrying it through repeated changes until it is brought to the perfected design appropriate in every way to the idea. Some may not be fortunate enough to get a full equipment so that all of the various kinds of metal work may be done, but such may be able to make a beginning by doing light work in saw piercing, which requires a very limited equipment. ”

“ Watch the enamel as the firing goes on and when it settles and glazes the heat should be withdrawn. The object should be allowed to cool very slowly. Hurrying at this point only increases chances for accidents. If, when cool, it is found that the channels in places are not full of enamel, the object is again cleaned in the nitric acid, more enamel applied, and fired as at first. The cover is now ready to finish. The enamel may be stoned down level with the top with an emery stone, or it may be left just as it comes from the fire in the first place. ”

“ The most satisfactory color that can be given copper is a bronze which comes naturally if left to come in contact with varying atmospheres. If the object has a good polished surface in the first place the color seems to become richer as time goes on. ”

“ Where a form is to be raised with the top edge turned in as at B, Plate 34, an anvil similar to the outline must be used. In raising a form like C, Plate 34, the sides are carried up as shown by the dotted lines and then the form is reversed and the neck part drawn in. A deep form is raised more quickly if, at the start, the metal is placed on a crinkling block and the edge crinkled. ”

“ Their length should be determined by the diameter of the joint, three times the diameter is the approximate length.
In making small hinges the projections may be bent into position by the use of the round nose plyers. In larger work the projection is fastened in the vise and [Pg 39] beginning at the end is bent around the pin a little at a time using the raw-hide mallet to work it into shape.
For small joints or hinges, such as would be used on a match box, stamp box, bon-bon box, or ink pot, the joint should be made of small tubing as described on page 110. ”

“ In this way irregularities in the design are less likely to occur than when the design is transferred with the carbon paper directly to the metal. The decoration may be pierced or embossed, according to one's choice. After the sawing or embossing has been done, it should be filed carefully and smoothed up with fine emery cloth to do away with crude and sharp edges. ”

“ The candle socket is made like the pattern as shown at D. It is bent cylindrical in shape and the ends are riveted together, then the laps on either side are bent nearly at right angles and serve to hold the socket in place. The cup is made from a circular piece of metal hammered into a slightly conical shape, E. A rod the length required is bent at right angles with a shoulder left at each end. The bracket is made next like the pattern F and bent into shape as at G.
When all the parts are finished, they are put together. Place the rod in a vise with the short end up. ”

“ In this, as in other work, it seems best to give each member of the class the same work for a while until he has become acquainted with the different tools and learned the limitations of the material. When this has been accomplished, each pupil may be allowed to work out his own designs. In this the educational value is very greatly increased. ”