Sheet Metal Bending Brake

Carol Dekle-Foss

Hello everyone! For today's post I am going to share a cool technique I picked up in one of my metalmith classes. It's a fun and easy way to create unique borders in your designs. I use the 18" bending brake from Harbor Freight. There is also this one available from Northern Tools, or if you are feeling extra crafty, you could make your own. You can find tons of tutorials online.

This is a bracelet I made for myself. It represents the Polar and Subtropical jet streams. I know, weird right?  I live here in California, and I have been watching our rivers and lakes over the last couple of months become the lowest I have ever seen them. So now I'm constantly looking up, hoping to see a storm front coming in or even a few reassuring clouds. I even did a little weather research and then became fascinated by our jet streams, and how they affect our weather worldwide.

So there you have it, a jet stream bracelet! Yep, I'm pretty much inspired by anything.

Let me share with you how to use the bending brake to create a border.

Parts list

Bending brake

Four clamps

Sheet metal

Hammer

Here is my bending brake clamped down to my workbench. I like it clamped down instead of bolted because when I'm done, I just store it away in a cupboard.

First, mark the metal where you want it bent. Then align perfectly along the edge where the brake will be lifted. 

Then place the metal bar on top of your piece and clamp it down tightly. 

Now lift! Duh, I realized I should have placed the clamps closer to the piece for a better lift. I also realized having the piece closer to an edge helps too. 

Also, be sure to anneal your piece first, to get a nice crisp line.

Now, lay your piece perpendicular to a solid surface (I used the bending brake) and lightly hammer down the border. You can use the channel to place something into it and then hammer down. Fabric? An etched piece? Lot's of design possibilities here.

Then, place on a metal surface and hammer the border down. Looking at this picture I realize my steel block is quite pathetic. Maybe I should have purchased a bigger one instead of a bending brake!

After hammering, you can then add a unique texture to your border.

Here is the cuff bracelet I made in class.

The bending brake is just another tool that you can add to your studio arsenal. I've only used it a couple of times but it's nice to have. I'm sure there are a ton of design possibilities. Let me know if you decide to get one and what you are going to use it for.

I hope this post inspires you to create something!

First attempt at making a silver sheet ingot

Carol Dekle-Foss

If you use silver or copper in your jewelry designs, at some point you will have to figure out what to do with your scraps. I've amassed about 10 ounces of sterling silver scrap and a MASSIVE amount of copper in about a 3 years time. It never appealed to me to turn in my silver scraps because I wouldn't be getting the amount invested in return. Especially now with silver prices so low and possibly dropping even more.

I've wanted to melt my silver into sheet ingots for rolling for awhile now, but honestly, I was too nervous. I had visions of it spilling and melting a hole in my toe! 

But.. I started thinking it's time. Time to do something with all the scraps I've accumulated and put them to use. So, with my husband taking pictures (making sure I don't burn the house down) I melted my first ingot yesterday! Yay! 

Here is how I did it and what I used. This is in no way a tutorial because I am still learning myself, but I wanted to share my results and a few things I learned along the way.

My supplies. 

The Ingot mold and Crucible I purchased at PMC Supplies on Ebay. I like the reversible one because you can make nice thick ring shanks. If you want to melt copper too, make sure you get the right ingot mold and crucible. 

Ohhh pretty flame. It's Photoshopped, I couldn't help myself! You get the idea though, you'll need a nice big beautiful flame!

The torch I use is a Smith Air/Acetylene torch, and for this project I used the #3 tip. 

First, I heated up the crucible and ingot mold. 

I then filled my crucible with a few pieces of silver and Borax. I guess Borax acts like a flux to help melt the metal quicker. After it started to melt, I added more pieces of silver.

Here we go!

When it started to get molten, I turned the crucible more to the side to get ready to pour. Anyone else see the creepy skeleton face?!?!!! WTH! Seriously. freaky.

And..pour quickly!

Ummm. yeah..epic fail. I poured too slowly and it created this interesting looking blob. Gotta pour fast!

I just reheated and poured again and got this. Much better. Although, I should have taken advantage of making the ingot shape smaller and it would have been a better shape. Oh well, next time!

So yeah..I made a boot. Hahahaha! That's okay, it's 20 gauge thick and will work well for backplates etc. Any suggestions on how to prevent cracking when rolling would be greatly appreciated. I did anneal it about 5 times. Maybe more annealing? 

What else have I been up to? I have a 2 day event coming up in September, so I have been preparing for that by making tons of earrings. 

I still have about 25 pairs to make, but here is what I've done so far.

I made these simple sterling silver earrings priced to sell at $18.00 each.  We will have to see how they do.

I then played with mixed metals and shapes by soldering together brass stampings to textured copper rounds.

I made these from some of my favorite ceramic beads my husband and I made.

I also played with a new shape and pattern for ceramic beads.

So that's what I've been up to! So what about you? Do you have tons of metal scrap just lying around? Have you ever done a metal scrap return? I would love to hear your thoughts.

Thank you for reading!

"Marriage of Metals" technique & tutorial

Carol Dekle-Foss

I learned this cool technique a couple months ago in my intermediate metalsmith class. I just LOVE it! I have always been attracted to geometric patterns and also mixing different metals. This technique was perfect for me to explore in my jewelry designs. These earrings are my latest creation, and for my first Boot Camp post, I'm going to show the readers of LMAJ how I made them. Tools & Materials on the bottom of the page.

Step one

Create the shapes you want on a computer software program such as Photoshop and print on regular paper.

Step two

Select your sheet metals, making sure they are all the same gauge. For the earrings I used sterling silver, copper and brass.

Step three

With a triangle, sharpie and a ruler, mark your shapes on the metal using the printout as a guide. Make sure your lines are a bit larger due to loss when cutting out and sanding. You will only need the basic geometric shapes for now.

Step four

 Cut out the sheet metal. I prefer a metal shear for the most accurate cuts. Here is my throatless shear from harbor freight. It's great for cutting accurate lines, and saves me tons of time in the studio.

Step five

Place sandpaper on a flat surface and run metal edges over it lightly to remove burs and even out the metals edges. 

Step six

Place metal pieces on flat surface and line up making sure every piece touches with no gaps for best results. Also for earrings, position pieces to form a mirror image.

Next, flux and then with the flux brush pick up solder pieces and place where joins meet. In the pic below you can see the solder pieces positioned. I cut them in thin rectangle shapes to try and prevent solder from flowing all over the metal, and hopefully to only go in the cracks of the joins. Keep in mind, solder flows wherever the heck it wants too anyway.

Step seven

Solder the pieces with a fairly large flame. Copper and brass have a higher melting temperature so you want to focus your flame on those pieces and avoid the sterling silver so you don't melt it. I use the Smith torch purchased from Cyberweld. This is where my teacher referred me to purchase mine in case you are in the market for one. NOTE: Soldering is a technique you have to practice to master. It takes time and patience, so don't be too hard on yourself if you are having difficulty. I know I struggled for a long time. If you want to learn I recommend taking a metalsmith class, or find a mentor to teach you the basics. If you have specific questions feel free to contact me and I will try to help! Also if you haven't discovered Nancy Hamilton you are in for a treat! She is so much fun to learn from. Here is a youtube video from her on soldering basics.

Here is the front of the pieces after pickling. You can see the solder flowed through in some areas. The back is a hot mess, as you can see in the below pics.

Step eight

Place paper shape onto metal and mark with sharpie. Then cut out with jewelers saw.

Step nine

 Sand edges with a belt sander or a bastard file.
Here is my sander from Harbor Freight. Again, a major time saver, and you can't beat the price. I hate filing and will avoid it at all costs.

Next, place the piece on top of the other and line up. Mark with sharpie and then saw out with jewelers saw.

Final finishing techniques

Ok, here are the two pieces. One is the front, and one the back. Yucky solder flow right? The next steps are all finishing techniques. So for my next post, which is scheduled for this Wednesday, I will show how I got the pieces to look like the above earrings! Plus some awesome techniques to speed up your finishing.

Here are some other designs utilizing the above technique.

My first pair of earrings finished in class.

For this necklace I used a lentil bead from Heather Powers of Humblebeads. I fell in love when I first saw it! 

 She was inspired by the Vincent Van Gogh Sunflower painting below. 

I used the "marriage of metals" technique and combined brass and bronze to form the vase. I then soldered it to a solid copper backing.

I love this technique and feel the design options are endless. So what do you think? Is it something that you might want to try? I would love to hear your thoughts!

TOOLS & MATERIALS
Torch                                                            
pickle pot
solder, medium
flux
different sheet metals
geometric shapes on paper
sandpaper, various grits
permanent sharpie, fine tip
jewelers saw
Photoshop or similiar program
paper
Sheet metals
triangle
metal ruler
sander or bastard file
metal shear
flat soldering surface
safety goggles
dust mask