Hi Folks,
Thank you all for encouraging Maria. She made her final choice on May 1 to attend Siena College in NY. An exciting milestone for her. Today we began making her wrist escutcheon. I loaned her my old copy of Great British Gunmakers by Neal and Back and she used it as inspiration for her own design. Here is what she came up with.
It was ambitious and I warned her she would need to carve that complex of acanthus leaves at the bottom. I suspected rightly that it would present an obstacle but that is part of learning. So we went forward with her design and took a slab of green carving wax, hollowed out the back and glued it to a piece of PVC pipe. Then we rounded the top as well. When that was done, we glued her paper pattern on the wax and she pricked the main lines and details into the wax through the paper using a needle held in a pin vise handle. When that was done, we removed the paper pattern and she carved the outline of the escutcheon in the wax.
Unfortunately, carving those delicate leaves caused a break in the thin wax at the bottom and another break occurred at the top. No worries, wax can be repaired by melting more wax on top. We decided to just lump some extra wax on some of the fragile leaves and carve the details after casting the plate in silver. Metal is stronger and can preserve fine details better. So she finished the wax as best she could and then we carved/chipped it off the PVC.
Next, Maria made the Delft clay mold.
Then we heated sterling silver in a crucible using my oxy-acetylene torch and poured the mold.
It took 3 tries to get it right. I could not figure out why it did not work the first time. I was using sterling silver melted from sheet silver and had some problems with it in past castings. On the third try, I added 50% fresh casting grain and the rest the melted sheet silver. It worked great. I believe the melted casting grain flowed into the mold better. Anyway, we now have an escutcheon with which we can work to engrave and carve the details.
While letting the mold cool, Maria did some final shaping of the stock and began the whiskering process. We stained the stock red with scarlet aniline dye dissolved in water. When she has scraped and sanded off all the color, she has whiskered the entire stock. Then we will finish the barrel tang carving and inlet the wrist plate.
dave