traditional cylinder shell construction

Traditional Cylinder Shell Construction

Italian (or better said Italio-American) style

Introduction of materials, tools, and techniques for building cylinder shells.

The construction method derives from Italians that migrated to the USA and continued their efforts Stateside. Hence Italio-American.

Techniques blend even further with the change of materials that are available per generation. Technology such as the internet spawns self starters which also initiates change from tight knit family type operations.

Introduction

As more people enter the hobby, their reasoning or interpretation changes based on what materials are available to the fireworker.

Sometimes this is a good thing and sometimes a bad thing. Must fully understand task at hand when modifing!

Best to avoid short cuts. Short cuts usually revert to inferior material and/or design.

Please ask questions as we progress!

Introduction

“The intent of the Fulcanelli article was to describe the typical catalogue shells that an Italian-American company would have made fifty years ago and the method that was used to make them. That method is a simplification of the methods used earlier and still used for shells larger or longer than those listed in the article”

Quote from Mike Swisher

Pyrotechnica IX (April 1984) Pyrotechnica XI (June 1987)

◦ Books can be found online at some pyro suppliers American Fireworks News (AFN) Warren Klofkorn of Prometheus

(prometheus.publications@cox.net)◦ Passfire.com◦ Fireworking.com◦ Amerature Pyrotechnics and Chemistry (APC)◦ RecPyro Google Group

Sources

Club Members Pyrotechnics Guild International (PGI) A good mix of interaction with different

people is needed to share all items pyrotechnic!

Sources

It’s all about $$$$! Use what you can get your hands on!

◦ Maybe….maybe not.

Some tools and material can be made to save money.CharcoalFormers

Avoid inferior material as much as possible.Corrugated cardboardWeak spolette tubes

Sourcing Tools and Material

Formers Calipers Spiking Tools Spolette Tooling Canulles Turacciolo (plug for

break) Spolette Rammer Awl or punch

Different Paper Cutters Brushes Blender Screens Dead Blow Hammer Shell Roller Alpax Circle Cutter Shell Press Forstner Bits

Tools for Cylinder Shells

Paper Paste String Shell Case End Discs Liners Paste Wraps Black Match Burst

Garnitures◦ Stars◦ Comets◦ Inserts

Pipe (for passfire) Spolettes Time Fuse Buckets Passfires Lift

Shell Construction Components

Paper Grain Direction

Grain Long

Grain Short

Paper Grain Direction

Grain Short

Grain Long

The following tables are slightly modified from the Pyrotechnica books mostly to accommodate the inclusion of 7” cylinder shell construction As I interpret the dimensions needed!

Shell Size Case Former Diameter

Minimum Length of Former

(Nominal shell size x 2 plus 1”)

3” 2-1/2” 7”

4” 3-1/2” 9”

5” 4-1/2” 11”

6” 5-1/2” 13”

7” 6-1/4” 14”

8” 7-1/4” 16”

10” 9” 19”

12” 11” 25”

Case Former Dimensions

Paper Weight Paper Thickness(in inches)

30 lb .003”

40 lb .004”

50 lb .005”

60 lb .006”

70 lb .007”

90 lb .009”

Kraft Paper Weights and Thickness

70 pound paper is normally used. Thinner paper could be used and would require additional turns.

Shell Size Number of Turnson Former

Paper Length

3” 3 24”

4” 4 48”

5” 5 3 each 24”

6” 6 4 each 24”

7” 7 3 each 48”

8” 8 4 each 48”

Kraft Paper Sizes for Cases

Shell Size Number of turnsOn former

Paper Weight Paper Length

3” 3 30-40 lb. 24”

4” 4 50-70 lb. 48”

5” 5 60-70 lb. 3 each 24”

6” 6 60-70 lb. 4 each 24”

7” 7 60-70 lb. 3 each 48”

8” 8 70 lb. 4 each 48”

Paste Wraps for Single Break Canister Shells 

Shell Size Canulle Diameter

3” 3/4” – 1”

4” 1” – 1-1/4”

5” 1-1/2” – 1-3/4”

6” 1-3/4” – 2”

7” 2” – 2-1/4”

8” 2-1/4” – 3”

Canulle Diameter

Shell Size Verticals/Strands Material

3” 12/2 8 Ply Cotton

4” 16/2 8 or 10 Ply Cotton

5” 24/2 8 or 10 Ply Cotton

6” 32/2 8 or 10 Ply Cotton

7” 32/2 - 48/2 8 or 10 Ply Cotton

8” 48/2 8 or 10 Ply Cotton

Standard Spiking Patterns

Shell Size Inside Dia. Outside Dia. Length Powder Charge

3” 5/16” .55” 2” 1” – 1-1/4”

4” 5/16” – 3/8” 11/16” 3” 1-3/8”

5” 5/16” – 3/8” 11/16” 3” 1-3/8” – 1-1/2”

6” 5/16” – 3/8” 11/16” 3” 1-1/2”

7” 5/16” – 3/8” 11/16” 3” 1-1/2 – 1-3/4”

8” 5/16” – 3/8” 11/16” 4” 1-3/4”

Spolette Information for Single Break Shells

Shell Size Delay Time (seconds)

3” 3

4” 3.5

5” 4

6” 5

7” 5-6

8” 6

Time Fuse Delay Times

The length of fuse will depend on the burn rate for that particular fuse. Usually 3 seconds per inch is close but does need to be verified!

Time fuse not recommended for cylinder shells!

Shell Size Description Weight of 2FA Lift Powder

3” Color or Salute 1 oz

3” Color and Inserts 1-1/4- 1-1/2 oz

4” Color or Salute 2 oz

4” Color and Inserts 2-1/2 oz

5” Color or Salute 3 – 3-1/2 oz

5” Color and Inserts 4 -5 oz

6” Color or Salute 4-5 oz

6” Color and Inserts 4-1/2 – 6 oz

7” Color and Inserts 6 - 7 oz

8” Color 8 – 12 oz

Lift Charge Amounts for Single Break Shells

Wheat Paste Mix as directed on package. Usually heavier paper will need more water

and lighter paper will need less. Recycled paper will like less water.

Maltese Paste 900 grams water 600 grams Elmer’s white glue 120 grams wheat paste (dry) 10 grams Potassium or Sodium Benzoate (preservative)

Paste