This was one of my very first metal working projects, made during a class with the late Edith Sommer at the Palo Alto Art Center.
I haven't been up to the art center's jewelry studio in many years, but back then it was well equipped and supported by a vibrant group of instructors and students. I hope it still is! |
The design is a simple Arts & Crafts era theme of straight lines and geometric shapes.
Themes like this one were used for everything from book covers to door lock plates. Similar designs are available commercially today. |
Because this project was made long ago, I don't have any in-process shots to show how it was made. Instead, I'll described how I made it and the tools and materials that went into it.
Not a lot of sophisticated fabrication was required for this project. The back plate and overlay shapes were sawn out of the copper sheet with a jeweler's saw and finished with files and sanding sticks.
This project gave me an appreciation for just how much heat it takes to get thickish copper up to soldering temperature. To make it work, I asked another student in the class to use a Prestolite air/acetylene torch to just generally heat the work while I used another one to heat each joint and flow the solder.
We even managed to avoid burning each other in the process... |
The oxides from soldering were pickled off and then piece was given a matte finish with gray Scotchbrite.
For pickle, I just use pHMinus pool chemical from the hardware store in an elCheapo slow cooker. pHMinus is the same stuff that's sold as Sparex, but more pure and a lot less expensive. |
The four corner mounting holes were drilled the same diameter as one side of the shank of the copper boat nails. Then the holes were squared off with the jeweler's saw and finished with a square cut needle file.
The die-struck heads of the copper nails were tidied up with a file. |
The last step was to mount the generic doorbell button.
I had to partially disassemble the button to mount it, but it fit right into the hole, the bezel pulled down tight against the surface, and it went back together easily. |
Undersized pilot holes were drilled in the wall, the wiring was moved from the old button to the new button, the button was tested, and then the nails were tapped into place with a plastic mallet (maybe a bit too vigorously on the bottom ones?).
The picture shows the plate after many years of exposure to Northern California weather. I like freshly finished copper, but the patina copper naturally acquires over time has its own appeal. |