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MobileUsers -
1. With a rough sketch to go by, I made this clay model. -
2. The clay model was dipped in hot "Dip Seal" and pulled out. -
3. The Dip Seal solidifies in a few seconds, and here the rubbery Dip Seal skin has been cut and removed. -
4. Skipping over a couple steps, the Dip Seal skin was spread out on paper to make a pattern, which was traced onto 16 gauge brass sheet and cut out. Here you see the first step of forming, the head pushed out with a ball-end punch on the hydraulic press. -
5. Moving the metal on the raising stake with the raising hammer. -
6. What it looked like after the first stage of raising. -
7. A little more forming on the bill, using the stake shown in the upper half of the picture. -
8. The piece has been annealed, and now it's getting punched in the head for a second time. -
9. What it looked like after step 8. -
10. Second stage of raising completed. -
11. Annealing again. -
12. All the previous steps have been repeated a third time. Checking the angle with a gauge I set from the clay model. -
13. Using a heavy planishing hammer on the neck on a curved stake. -
14. Using the special tool on the left to push down both side of the bill at the same time.