Making a Beaten Metal Dish

Stage 1

Use the Gabro Guillotine to cut a square of Aluminium

Stage 2

Use a Rule and a Scriber to find the centre of the square

Stage 3

Place the metal on a hard surface and Centre Punch the middle of the square

Centre Punch

Stage 4

Use Dividers to mark out a circle on the Aluminium

Dividers

Stage 5

Use the Guillotine or Tinsnips to trim the metal to the circle.

Guillotine

Tinsnips

Safety - Remember

1) Only one person is allowed to use the Guillotine at a time

2) Keep your fingers well back from the cutting edge

Stage 6

Use a File, then Emery cloth, to remove any corners from the aluminium disk

Dividers

Stage 6

Rim

Use the dividers to mark out the rim of the dish

1. Care should be taken when carrying hot metals (particularly metals at black heat that may not appear hot)

2. Clay bricks should not be heated as they can disintegrate violently.

3. Ceramic chips remain hot for a considerable time after the heat source has been removed.

4. Foreign materials present in the forge can cause fumes. Stones can explode.

5. Quenching of hot materials, particularly tubular components can cause risk of scalding.

6. Fuel combustion can produce dangerous gasses.

Pupils should be aware of the following hazards

Conditions of use.Appropriate safety equipment must be worn: Goggles, Leather gloves. (Leather apron where appropriate)

The Forge

The Forge

Hearth

Canopy

Fire Bricks

On / Off Switch

Isolating Switch

Ceramic ChipsSpark Ignition

switch

Brazing Torch

Spark

Blacksmiths Tongs

Stage 7

Anneal the Aluminium disk

1

2

3

1. Mark with soap

2. Heat until soap turns black

3. Quench

Stage 8

Hardwood Block

Panel Pins

Make a sinking block

The sinking block is made from a piece of hardwood and two panel pins. The pins are positioned so the edge of the wood is level with the rim of the dish

Block Edge

Stage 9Commencement

of sinking

Use a Ball Pein hammer to strike down on the aluminium disk as shown then rotate the disk and repeat this process.

X

X

XXXX

XXXX

XXXX

X X

Blocking

Hammer

Strike the Disk in the positions marked X

For better results use a Blocking Hammer

Stage 10

As you hammer the aluminium it will work harden and will need to be re-annealed after each round of hammering.

1 Soap 2 Heat 3 Quench

Annealing

Stage 11

This process of sinking then annealing may need to be repeated 10 to 15 times to achieve the desired results.

Occasionally you will need to flatten the rim of the dish. This can be done with a scrap piece of wood as shown

Stage 12

Once the dish has been hollowed it can be cleaned with emery cloth then wet and dry silicon carbide paper.

Clean the dish thoroughly.

Stage 13

Use a Round Stake and a Repousse Hammer to produce a dimpled pattern all over the dish

(Take care not to strike the face of the stake directly with the hammer as this will leave a dimple and damage the stake)

Repousse Hammer

Round Stake

Stage 14

Cover the whole dish with the dimpled pattern

Stage 15

Finally use some metal polish and a rag to clean the dish

The End