making a beaten metal dish. stage 1 use the gabro guillotine to cut a square of aluminium
TRANSCRIPT
Making a Beaten Metal Dish
Stage 1
Use the Gabro Guillotine to cut a square of Aluminium
Stage 2
Use a Rule and a Scriber to find the centre of the square
Stage 3
Place the metal on a hard surface and Centre Punch the middle of the square
Centre Punch
Stage 4
Use Dividers to mark out a circle on the Aluminium
Dividers
Stage 5
Use the Guillotine or Tinsnips to trim the metal to the circle.
Guillotine
Tinsnips
Safety - Remember
1) Only one person is allowed to use the Guillotine at a time
2) Keep your fingers well back from the cutting edge
Stage 6
Use a File, then Emery cloth, to remove any corners from the aluminium disk
Dividers
Stage 6
Rim
Use the dividers to mark out the rim of the dish
1. Care should be taken when carrying hot metals (particularly metals at black heat that may not appear hot)
2. Clay bricks should not be heated as they can disintegrate violently.
3. Ceramic chips remain hot for a considerable time after the heat source has been removed.
4. Foreign materials present in the forge can cause fumes. Stones can explode.
5. Quenching of hot materials, particularly tubular components can cause risk of scalding.
6. Fuel combustion can produce dangerous gasses.
Pupils should be aware of the following hazards
Conditions of use.Appropriate safety equipment must be worn: Goggles, Leather gloves. (Leather apron where appropriate)
The Forge
The Forge
Hearth
Canopy
Fire Bricks
On / Off Switch
Isolating Switch
Ceramic ChipsSpark Ignition
switch
Brazing Torch
Spark
Blacksmiths Tongs
Stage 7
Anneal the Aluminium disk
1
2
3
1. Mark with soap
2. Heat until soap turns black
3. Quench
Stage 8
Hardwood Block
Panel Pins
Make a sinking block
The sinking block is made from a piece of hardwood and two panel pins. The pins are positioned so the edge of the wood is level with the rim of the dish
Block Edge
Stage 9Commencement
of sinking
Use a Ball Pein hammer to strike down on the aluminium disk as shown then rotate the disk and repeat this process.
X
X
XXXX
XXXX
XXXX
X X
Blocking
Hammer
Strike the Disk in the positions marked X
For better results use a Blocking Hammer
Stage 10
As you hammer the aluminium it will work harden and will need to be re-annealed after each round of hammering.
1 Soap 2 Heat 3 Quench
Annealing
Stage 11
This process of sinking then annealing may need to be repeated 10 to 15 times to achieve the desired results.
Occasionally you will need to flatten the rim of the dish. This can be done with a scrap piece of wood as shown
Stage 12
Once the dish has been hollowed it can be cleaned with emery cloth then wet and dry silicon carbide paper.
Clean the dish thoroughly.
Stage 13
Use a Round Stake and a Repousse Hammer to produce a dimpled pattern all over the dish
(Take care not to strike the face of the stake directly with the hammer as this will leave a dimple and damage the stake)
Repousse Hammer
Round Stake
Stage 14
Cover the whole dish with the dimpled pattern
Stage 15
Finally use some metal polish and a rag to clean the dish
The End