Copper Work Part 3

Box No. 3, Plate 24.

[Ill.u.s.tration: PLATE 24. STAMP BOX]

[Ill.u.s.tration: PLATE 25. STAMP BOX COVER DESIGNS]

Take a strip of metal as wide as the required depth of the box and as long as the sum of the four sides. The length of each side is measured off on this strip and a line scratched at right angles to the edge. The strip is then placed over a block of metal and, with a rawhide hammer bent at right angles at scratched lines, making three corners, leaving the ends to meet at the fourth corner where they are to be soldered.

These ends should be mitered as in Box 1, before soldering. After the corner has been soldered and the box pickled, it is again placed over a block and trued up square. Having decided which is to be the top and which the bottom of the box, file the bottom edges level and at right angles to the sides. A piece of metal is then cut for the bottom large enough to allow about 1/16" to project on all four sides.

It is then prepared for soldering and bound together with iron wire, Figure 20. The solder should be cut in small pieces and placed about the inside edges. In soldering the bottom, care must be taken not to unsolder the corner. This may be avoided by keeping the flame away from the soldered corner until the rest of the solder has run, applying it to the corner at the last and only for a fraction of a minute.

After the soldering, the box is pickled and the edges of the bottom filed square. The 1/16" that was allowed to project may be filed flush with the sides of the box or left to project a little.

The cover is made by taking a strip of metal about 3/16" wide and long enough to fit around the inside of the box. The length of the sides (inside measurement) is laid out and then bent over a block as previously described. The corner is soldered and the upper edges are filed off level and soldered to a piece of metal, forming the top. This strip on the inside keeps the cover in place. If the design on the cover is to be carried out in enamel it should be done after the cover is completed. If the design is to be embossed, it should be done before the strip which holds the cover in place is soldered on.

[Ill.u.s.tration: PLATE 26.]

Box No. 4, Plate 24.

The body of this box may be made like either No. 1 or No. 3. An addition is shown on this one which allows the stamp to be taken from the box more easily. A strip of 20 gauge metal 1/16" wide is soldered on the inside next to the top edge extending from one end to the other as shown in the section at D. Another piece of the same gauge metal is cut, in length equal to the inside length of the box and about 1/4" wider than the box. This is placed inside the box and sprung into place as shown at C in the section. This device may be applied to either of the other boxes.

The cover of this box is made of but one piece and hinged with a strap hinge, which also forms the cover decoration.

To give the surface of the metal of this box a bold hammered surface adds much to its attractiveness.

MATCH BOX.

The Match Box may be made in the same way as the Stamp Box with the exception of the cover. It seems better to have the cover of the match box hinged. The hinge may be made so as to form a part of the decoration of the cover by making it a strap hinge as shown at Plates 15, 16, 17.

The hinge may also be made of tubing and extend across the back of the box. This method leaves the cover to be decorated in some other way, either by embossing or by enameling or by both.

[Ill.u.s.tration]

[Ill.u.s.tration: PLATE 27. MATCH BOX]

[Ill.u.s.tration: PLATE 28. MATCH BOX COVER DESIGNS]

Chapter V.

SCONCE A.

The pattern for this sconce as shown at Plate 29A is transferred to the metal which is then cut out. The part which serves as a reflector is raised by placing the metal face down on a sand bag, or on pitch and with the pein end of a chaser's hammer or with a pointed horn hammer, driving the center down to the required depth. If the face is somewhat irregular, it can be trued up by placing it on a block of wood and going over it with a rawhide hammer.

The shelf on which the candle socket rests is formed by bending the lower part of the sconce at right angles as shown by the dotted line.

The projections at 2, 3, 4, Plate 29A, when bent into shape as shown on Plate 29 form the supports for the candle socket. The projection at 5 Plate 29A when bent into shape serves as a bracket to support the shelf.

The candle socket is made from a strip of metal bent into cylindrical shape with the ends riveted together. When the socket has been riveted and holes drilled as indicated, the sconce is finished according to taste and mounted on a back of wood stained to harmonize with the color of the metal.

[Ill.u.s.tration]

[Ill.u.s.tration: PLATE 29. SCONCE A.]

[Ill.u.s.tration: PLATE 29 A. SCONCE A.]

[Ill.u.s.tration: PLATE 30.]

SCONCE B.

A rectangular piece of metal is cut out about 1/2 inch larger on all sides than the design calls for and given a hammered surface with the pein end of a large hammer. After the design has been transferred to the back of the metal, it is then placed on pitch face down, and with a suitable tool the lines are sunk at A and B, Plate 31, about 1/16", as shown in the section at C. It is then removed from the pitch and, after cleaning, is put over a sand bag face up, and with a rawhide hammer, the part that is to serve as a reflector is concaved a little.

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. The cup is put over the pin at H, and also the socket, so that the pin pa.s.ses through the holes in both laps. The pin is then headed up, holding all securely in place. The bracket is next riveted to the back at K, through which the rod is put, the pin pa.s.sing through the back is headed up at L. After finis.h.i.+ng, the sconce may be mounted on a wood back.

[Ill.u.s.tration]

[Ill.u.s.tration: PLATE 31. SCONCE B.]

PICTURE FRAME.

This object is made as follows: Take a piece of metal quite a little larger than the outline of the frame that is to be made. Draw on this piece of metal the outline of the frame and also the extensions which are folded back to give the thickness necessary for the reception of the picture, gla.s.s, and back, as shown at B. Have the side opposite to that on which the drawing is done free from scratches as it is to serve later as the front. Any decoration that is used must be of the simplest sort.

This decoration may be pierced or in repousse. The frame here ill.u.s.trated and the plate of designs were intended for repousse as more satisfactory results have been obtained by this process. After the design for the decoration of the front of the frame has been transferred to the same side of the metal as the outline, it must be prepared for the repousse process. This is done by placing it on a pitch pot. The pitch is softened enough so that the metal will stick to it. After placing the metal on the pitch, work a little of the pitch over the edges as this will hold it more securely. It is then allowed to cool or harden before working. With a suitable tool and hammer, after the pitch is hard, follow the lines which make up the design or decorative part of the frame. The lines should be gone over lightly, slowly, and carefully at first until the design is fairly well started; then they may be gone over again, sinking them a little deeper each time until they have been carried deep enough to give the design the required relief on the face of the frame. For this part of the work the tool should not be used as a punch, driving the metal down in one place and then moving it to another and so on, but it should be kept moving all the time and should at the same time receive a repeated number of light blows from the hammer. By so doing the face of the work will be smooth, otherwise each blow from the hammer will show.

[Ill.u.s.tration: PLATE 32. PICTURE FRAME]

If there is doubt as to the depth to which the lines should be carried, the work may be taken off the pitch occasionally, so that the face may be seen. It is not an easy thing to reduce relief in this work, therefore it is better to go carefully working it up slowly. After the repousse part of the frame is done, clean it with kerosene and pickle.

The corners may then be cut out as at B, filed up square, and beveled as in the box. The sides are then bent back over a block of wood or metal, bringing the corners well together. They are then soldered. A metal saw is used to make the opening, A, the edges of which are then filed up square.

The back for this frame is made in the same way as the front except that it is left perfectly plain. This should be made to fit inside of the frame tight enough so that no fastening will be needed to hold it in place.

A frame of this size and kind may be made to hang or to stand. If it is to hang, a small ring may be made and fastened to the back as shown at C. If it is to stand, a support of some kind such as is shown at D is needed. This is made of the same thickness metal as the frame and may be made in many outlines. This support may be made stationary by riveting it to the back, or hinged, which is much better, as is shown at E and F.

The hinge is made by taking a piece of about 1/8" tubing and cutting three pieces, making one of the pieces equal in width to the other two and having the three equal in width to the top of the support. The two short pieces are soldered to the back and the long piece to the support.

A piece of wire equal in diameter to the hole in the tube is then cut and put in place which hinges the back and support together.

The method of making the tubing used for the above is described on page 100.

[Ill.u.s.tration: PLATE 33. PICTURE FRAME DESIGNS]

SOLDERING.

A piece of silver solder, a slate slab such as is ordinarily used for grinding ink, powdered or lump borax, and a soft hair brush of some sort are all that is necessary for the process of soldering in addition to what we already have.

The pieces of metal that are to be soldered must be absolutely free from all foreign matter. To insure this the joint is sc.r.a.ped 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.