Fabricating in Bronze

[Bob Smalser]

http://pic3.picturetrail.com/VOL12/1104763/7652151/100594402.jpg

Starting with a salvaged gooseneck screwed and brazed to a mounting block, some 1/8 X 2 silicon bronze strapping, and a bending jig made to fit the strapping's thickness ....

http://pic3.picturetrail.com/VOL12/1104763/7652151/100594388.jpg

...the bronze is heated red and a 90-degree bend made.

http://pic3.picturetrail.com/VOL12/1104763/7652151/100594393.jpg

The mast circumference it measured...

http://pic3.picturetrail.com/VOL12/1104763/7652151/100594386.jpg

...and the distance is derived to the next bend.

http://pic3.picturetrail.com/VOL12/1104763/7652151/100594382.jpg

The second bend is made so when the band is formed and the two bends butt, they are the derived circumference.

http://pic3.picturetrail.com/VOL12/1104763/7652151/100594750.jpg

The workpiece is placed in an "oven" and heated to red...

http://pic3.picturetrail.com/VOL12/1104763/7652151/100594744.jpg

...then while red, bent around a form made to the exact diameter of the mast.

http://pic3.picturetrail.com/VOL12/1104763/7652151/100594739.jpg

Then the workpiece is placed back into the oven, heated red for a second time, and immediately quenched in water to anneal (soften) it.

Continued….

[Bob Smalser]

http://pic3.picturetrail.com/VOL12/1104763/7652151/100594731.jpg

The rough workpiece is cleaned to check for cracks...

http://pic3.picturetrail.com/VOL12/1104763/7652151/100594737.jpg

...and gently shaped to its final form in place on the mast, which has been padded with tarred cotton friction tape.

http://pic3.picturetrail.com/VOL12/1104763/7652151/100594956.jpg

Cold forming continues with the gooseneck mounting block in place to mark the cutoffs...

http://pic3.picturetrail.com/VOL12/1104763/7652151/100594952.jpg

...and pilot holes are drilled in place for the mounting bolt.

http://pic3.picturetrail.com/VOL12/1104763/7652151/100594949.jpg

The pilot holes are drilled to size in the vise, the assembly buffed, and assembled in place. All that's left to be done is to cut the SS allthread and add the decorative acorn nut.

http://pic3.picturetrail.com/VOL12/1104763/7652151/100519424.jpg

The jib halyard block is done the same way.

[Dan Forman]

Bob---Is there anything you DON'T know how to do? Thanks for showing us these very interesting facets of your work.

Dan