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|INLAYING METAL SHEETS|
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Opposite is a nickle silver sheet with an inlay of copper.
|Put pallions of solder on top of a bottom sheet, ensuring that it has been cleaned and fluxed. Rest the top sheet on the bottom sheet. Heat with a gas torch until the solder flows, forming a ‘line’ of solder around the join / edge. This is called ‘sweat soldering’. The metal is then cleaned in a pickling bath etc.... ready for the next stage.|
|Using a punch and carefully delivering taps from the hammer, undercut the edge, forming an angle. Alternatively, before soldering, use a file to produce the angle along the inner edge of the top sheet.|
|Cut out a piece of annealed copper, so that it fits accurately, into the rectangular slot. The copper should be slightly thicker than the recess it fits into, standing above the surface. A wooden mallet may be needed, to tap the copper in position.|
|Either, place a metal block on the copper and firmly tap round it, forcing the copper into the dovetailed edge.
Use a flat punch to tap around the edge of the copper, again pressuring the copper into the angled edge.
Clean up the surface with a file, abrasives and finally polishing.
|An alternative method of manufacture, is to use a single sheet, from which a rectangular area is etched out to a certain depth, OR cut / carved out using gravers and punches. This avoids the need to ‘sweat solder’ two sheets together. However, it can take much longer to complete.|
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