DIY Metal Smithing

Metal smithing is the process of cutting, forging, manipulating and connecting metal pieces into forms such as jewelry, sculptures and vessels. Three commonly known metal smiths are the blacksmith, silversmith and goldsmith. Steel, copper, silver, gold, nickel silver, brass and nu-gold are just a few of the metals metal smiths use to complete hand-forged projects. The metal-smithing process uses tools such as a jeweler's saw, third hand (lock tweezers attached to a rotating arm), rawhide mallet, anvil and a cleaning solvent called a pickle solution.

Things You'll Need

• 20-gauge metal
• Paper
• Pencil
• Scissors
• Rubber cement
• Bench pin
• Jeweler's saw with blade
• Drill
• Drill bit
• Needle files
• 400-grit sandpaper
• Third-hand
• Flux
• Artist paintbrush
• Silver solder
• Scissors
• Safety glasses
• Torch with 0 tip
• Striker
• Copper tongs
• Glass container with lid
• Pickle solution
• Water
• Towel

Instructions

Cutting the Metal

1. Draw a 2-inch design on a piece of paper. Draw a 1 1/2-inch copy of the first design with a shape in the center. Designs include squares, circles, ovals, stars and so on. Cut out the design.

2. Spread a thin layer of rubber cement over the back of each cutout design. Immediately glue the two design shapes along the edge of a piece of 20-gauge metal.

3. Position the edge of the 20-gauge metal so the design is along the bottom edge. Place the 20-gauge metal on the edge of a pin vise attached to the edge of a workbench or a table.

4. Position the jeweler's saw so it is perpendicular to the edge of the metal. Move the saw striaght up and down to cut through the metal. Repeat the process on the second shape. Note: The blade will break in the saw when positioned at an angle.

5. Drill a small hole through the design on the inside of the 1 1/2-inch pattern. Unhook the sawblade from the jeweler's saw. Place the sawblade through the hole. Reattach the sawblade and position the blade perpendicular to the metal to cut.

6. File the edges of the cut piece of metal with a needle file. File straight edges with a flat or triangle needle file. File curved edges with a round needle file. Sand all scratches from the surface of the metal with 400-grit sandpaper.

Soldering

1. Position the 2-inch metal shape in a third hand so the metal is horizontal. Brush a liberal coat of flux over the metal surface.

2. Cut 12 to 14 pieces of silver solder one-sixteenths-inch long. Place the pieces of flux approximately one-quarter-inch from the outside edge of the 2-inch piece. Position the second piece of cut metal over the first. Move the solder so it is under the metal if seen inside the cutout area of the design. Remove the second piece of metal.

3. Brush a coating of flux over the 1 1/2-inch piece of metal. Place the metal of the solder. Put on the safety glasses and light the torch.

4. Hold the flame approximately 2 inches from the metal surface. Move the flame in small circular motions. Watch the top piece of metal. The metal will drop when the solder is melted. Immediately turn off the flame.

5. Remove the hot metal from the third hand with a copper tongs. Immediately immerse the hot metal in the pickle solution. Allow the metal to soak for five to 10 minutes. Note: The pickle solution is placed in a glass container with a lid. The lid is opened and the metal is placed in the solution. Place the lid on the solution immediately after the metal is submerged. Toxic fumes are created from the reaction of the metal, heat and pickle solution.

6. Remove the metal from the pickle solution with a copper tongs. Rinse the soldered metal with water and dry.

References

• Mid-west Metalsmiths: Metalsmithing Tutorials