Today I 3D scanned a stone aged axe my Grandad found many years ago in England. I have always loved the shape and form of the tool and how it fits perfectly into the hand.
I wanted to use this form to create tools to make forms for pieces for the house.
I scanned the axe at the university and then used the files to create both silversmithing stakes and hammers.
For the stakes I kept the original size of the axe and added a section that would allow it to be gripped in a vice. For the hammers I scaled down the model to 85mm and cut out a hole for the handle.
I am planning on 3D printing the models and casting them possibly in bronze.
I have been working more on my egg cups this week. I just? I am now happy with the general shape of them. If there is one thing I am a little disappointed about it is that I have lost the thickness created by colquing the edge and then cutting it off.
I started planishing one of the cups. I soon found that there were a few lines still visible in the head of the hammer from the 3D printing. I sanded and polished these out before continuing.
Before planishing the cups I annealed the copper again and drew on lines as I did when raising. I then planished from the inside out twice and I may repeat this again. I am happy with the shine this has created.
I have been really enjoying raising metal in the workshop over the last few months. Aside from getting very toned in one arm, there is something very therapeutic about creating objects by hand.
I first cut out two disks 75mm radius. I later had to cut this down by about 12mm so I should have begun with 62-64mm. This means the edge on this piece will be thinner than I would like.
I have almost got them to the shape I like but want to bring in an egg next week to make sure they fit perfectly.
I plan to 3D print and cast matching bases for them.
I have been raising a small water jug which I intend to make into a set with two glasses over the next few weeks.
I used my 3D printed brass hammer to do most of the raising. I wanted to take a similar from to a traditional whisky tumbler only with a small spout.
I finished off the piece with my 3D printed steel texturing hammer which gave an interesting finish.
The last thing I did was hammer in the spout. I used the edge of a hammer to do this. I still have some finishing to do. I’m not entirely happy with the shape around the middle and around the rim.
I feel I may need to make a wooden stake to give me the right shape.
I am planning on 3D printing a base for it to stand as well as a matching handle.
Last week my handle for the raising hammer I made in Hungary was CNC milled in birch wood. It had taken quite a lot of time because previously it had been milled in oak. When I spoke to the wood technician he said that the grain of the wood was at an angle and that this would split when used. It brought up a very interesting conversation about the need for craftsmen and traditional crafts skills in the field of modern technologies. Not all items made using modern technologies will work or be better than something handcrafted but that it is the knowledge of both that are needed to apply ideas.
I glued the handle together in the workshop with wood glue and clamped together for around an hour.
When the handle was taken off the milling machine it had supports on the sides, I cut these off with a saw. I then filed and sanded the handle and fixed the hammer head in using epoxy resin.
I am now using Danish oil on the handle every day for the next week. I still have to drill a hole through both the handle and the head to fix a rod through.
I put together the raising hammer mold in exactly the same way as the sea horse mold.I found that at the casting stage of this I had problems.
I think I had placed the hammer too far down and as it was a little larger than the previous hammer, I needed an air hole in there.
I rebuilt the mold in the afternoon, placing the hammer closer to the top of the mold and with two air holes in to draw out the metal.
Later in the evening we went for a second pour.
This time the piece worked really well an I was ready to clean up both my claw hammer and raising hammer.
So right now I am in Mátranovák, Hungary. I have spent the last few days sand casting hammers in brass. The first one I tried was the seahorse claw hammer.
I made the sand casting mold in the usual way. First I compacted the sand into the bottom part of the mold. After scraping the sand flat I roughly carved out a space for the 3D printed hammer.
I compacted the sand flat around the centre line of the print and then coated in talc.
I added the top part of the mold and compacted the sand with a mallet. After reaching over the top line I scraped back the top so it was flat.
I then opened the mold and took out the 3D printed plastic hammer and the tube I used for the pour hole.
I placed the mold back together and clamped the edges.
I then took the mold to the local blacksmith Laci bácsi, who helped me cast the piece in Brass.
He first smashed up lots of pieces of coal into small pieces for the furnace.
He then lit the furnace with some small pieces of wood and then added the coal.
The mold was left close to the furnace to heat a little and was turned after ten minutes to heat the other side.
The metal was left to heat for around 20 minutes before it was liquid enough to pour.
After around five minutes after the pour the metal was solid enough to open the mold.
Laci bácsi and myself were both very happy with the result.
The hammer was quenched in water and I am now left with the task of finishing off the piece.
Today I ran a test print of my claw hammer I designed over the last few days on the UP printer. I wanted to check for size and scale and I may also take a cast from this into bronze. I am very happy with the feel, form and size. I am also going to 3D print one in hardened resin to test it’s durability. I haven’t quite decided on how I will produce the handle yet. I will be having a think about this over the next few weeks.
For the last day or two I have been designing a claw hammer for larger scale use such as building my house. I went through a few designs and decided I would make use of the CAD and design the hammer so that I wouldn’t have to wedge the handle at the top in a traditional way. I designed the handle and the hammer head so that they join in the handle shaft.
I got a little carried away with the handle when the hammer head started to look a little like a seahorse. I’m not sure if I will keep the base section exactly like this or if I will simplify it a little before production and comfort. I am hoping to cast the top section in bronze and get the handle either milled in wood or 3D printed in hard clear resin.
For the last few days I have been working on finishing my hammer. Initially I made a handle from an unknown wood I found in the park. After Finishing the wood beautifully to a high polish I went to wedge the hammer head into the top and the wood split.
I then started again using a piece of oak. I initially used my 3D printed chisel to carve the plank. Although this was still cutting really well, I had to sharpen it regularly to keep a good cutting edge.
After 3 hours of solid carving I hadn’t made that much of a dint in the wood. I went over to the wood workshop to see if I could use the lathe on it. Malcom the technician offered an even better solution. He showed me how to use a spindle shaver. This is a tool I had never heard of before. It is similar to a plane however you hold it with two hands and it has a handle on each side.With in about an hour I had carved a nice dainty shaped handle that was better proportioned to the hammer head.
I used my 3D printed chisel again to clean and scrape the wood before I sanded it.Finally I cut a wedge of walnut wood and a wedge out of the top of the handle. I then added a little artificial chemical bonding (wood glue) and wedged the hammer head onto the handle. I plan to polish the handle with Danish oil every day for a week or two.
I am very please with the result. I plan to tweak it a little over the next week, however I can wait to start using it to see how it holds up.