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Posted by Andy on May 6, 2008, 8:38 am
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> > In article
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> > > > CWChapl...@gmail.com wrote:
> > > > > Greetings. I have a brass air key from an antique musical instrume=
nt
> > > > > which I would like to see if I could have some sort of appliance m=
ade
> > > > > to duplicate it myself. The part is small ... ~5" long, formed
> > > > > brass ... looks like a spoon. Can anyone please make recommendatio=
ns
> > > > > for a casting set (punch & die?) to put in a hydraulic press? or
> > > > > perhaps a cast iron "hammer form". The part is ~140 years old, and=
is
> > > > > not replaceable, so perhaps I could make a mold of it, or preferea=
bly
> > > > > find someone to take on this type of project in the Maryland or
> > > > > surrounding states (to which I would be willing to drive). Someone=
> > > > > told me that the Amish have foundrys and are resonable in the
> > > > > costs ... ? All help, suggestions, etc., are greatly appreciated. =
Andy
>
> > > > It doesn't make sense to cast one part. =A0Most likely a good crafts=
man in
> > > > brass could duplicate the part from brass sheet. =A0If the design is=
such
> > > > that it can't be made from sheet (has a big block in one spot, like =
the
> > > > hinge, for instance) then it might be made in two pieces and joined.=
> > > > Experts in this type of fabrication can make hard solder joints you
> > > > can't even see.
>
> > > > Guessing at what the part looks like, investment casting might be th=
e
> > > > only way to cast something long and thin, and such parts are often q=
uite
> > > > difficult.
>
> > > > I'm not sure what you mean by "casting set (punch & die?)". =A0You c=
ast
> > > > molten metal in a mold, choices are such as sand casting, lost wax a=
nd
> > > > investment. =A0A punch and die would stamp a piece out of sheet meta=
l.
> > > > You can form the metal with a punch, too.
>
> > > > Jon
>
> > > Thank you for your reply Jon. I appoligize for my incorrect terms.
> > > What I was trying to describe is a two part set of ? what ever the
> > > term would be? that had the profile of the air key, where the bottom
> > > portion would be the underneath of the key, overtop of which would be
> > > laid a sheet of .032 brass, overtop of which would be the matching top=
> > > portion of the profile (less the thickness of the brass sheet. I was
> > > hopeing that this rid could then be put in a hydraulic press, pressed
> > > together to form the key, and I would be left with only triming,
> > > filing, and drilling, etc. to finish the piece.
> > > With the hammer form concept, the bottom profile would only be made,
> > > and I would need to use harwood punches to "tap" the form into the
> > > piece.
> > > I don't know what lost wax and investment are, however, once I finish
> > > with this post, I will do some research.
> > > Thank you again.
>
> > You might consider taking some photos and putting them up somewhere
> > available to the public. =A0Put a scale in the photo somewhere. =A0(Imag=
es
> > won't work on this newsgroup.)
>
> > Joe Gwinn- Hide quoted text -
>
> > - Show quoted text -
>
> Thank you for the suggestion Joesph.
> I posted three pictures at the following URL:
>
> http://www.flickr.com/photos/andyacc/
>
> I worked on this some last night, and thank God, I think that this is
> do-able with just some bending and dapping.
> However, I'm not there yet ... although I did get a crudely fashioned
> piece.
>
> I will post another question, however do you know of an easy way (I
> don't have many tools, or much money :-) to anneal
> the brass strip I am using. The portion of the long "spoon" that
> attaches to the round disc cracked as I formed it.
> I am hopeing that if I can properly anneal it, that I should be able
> to get this done.
>
> Thank you in advance.- Hide quoted text -
>
> - Show quoted text -
I forgot to give dimensions of the brass strip ...
~ 5" in total length (the part I wish to anneal is only one end ...
maybe a 1" portion)
~3/4" in width (to be trimmed later)
0.032" thick
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