Steve Adams
Elite Cafe Member
- Joined
- Jan 2, 2007
- Messages
- 320
Once upon a time, I learned to engrave steel dies with a hammer and chisels. A short time later, I learned how to make products from these dies in aluminum, copper, bronze, brass and pewter. You could use gold or silver if the cost doesn't bother you. Some of the products I've made or have cut dies for include trays, bowls, dishes, candle holders, coasters, jewelery boxes, waste baskets, mugs, belt buckles, ornaments, bookmarks, napkin rings, etc.
Here is the basic process: On a flat square block of tool steel, engrave in the negative the design you intend to hammer. I use S7, six inches square or larger steel, milled flat on both sides, then fine surface ground on one side. You should further sand the surface a bit smoother on the surface ground side. When engraving a die, start with the background of the design and work forward. The use of a hammer, chisels, a few punches, good light, a sturdy bench and an optivisor is all you need. Check work as you go with a hard clay block or silly putty.
Once the die is complete, place it on a heavy steel table that allows room for clamping to the side of the die. Put wood equal to the height of the die around the die then place masking tape on the seam where the wood butts up against the steel. You can hammer aluminum or pewter into a soft die, but you should harden the die if you want to use harder materials.
Place the material over the design on the die and clamp the metal in all four corners. Use whatever clamping system you want, I just use furniture clamps. The top two clamps should be very tight, the bottom two tight but a bit less. When you hammer the metal it stretches so the bottom two clamps will allow for the movement of metal. Tip - it helps to rub the metal with scotch brite so you can see your hammer marks.
Start hammering with a hard mallet. Go over the whole design. The design will start to show on the back of the metal. Now, take a polished ball peen hammer and start hammering in rows, being certain not to miss a spot. If the metal begins to buckle just flatten it out with the mallet, then keep hammering with the ball peen. Pay close attention to deeper spots in the die, you don't want to miss any deep areas with the hammer. If you miss a spot, the scotch brite surface will show where you missed. In this case, just re-hit that spot with the hammer.
When done, remove the clamps and see how you did. It takes a little practice, but works great.
Now just cut the metal to the shape you want, buff it, color it, buff a little more to get the color you want, form it and then shine it.
You can see my hammering set up on www.sga-sculpture-engraving.com
Here is the basic process: On a flat square block of tool steel, engrave in the negative the design you intend to hammer. I use S7, six inches square or larger steel, milled flat on both sides, then fine surface ground on one side. You should further sand the surface a bit smoother on the surface ground side. When engraving a die, start with the background of the design and work forward. The use of a hammer, chisels, a few punches, good light, a sturdy bench and an optivisor is all you need. Check work as you go with a hard clay block or silly putty.
Once the die is complete, place it on a heavy steel table that allows room for clamping to the side of the die. Put wood equal to the height of the die around the die then place masking tape on the seam where the wood butts up against the steel. You can hammer aluminum or pewter into a soft die, but you should harden the die if you want to use harder materials.
Place the material over the design on the die and clamp the metal in all four corners. Use whatever clamping system you want, I just use furniture clamps. The top two clamps should be very tight, the bottom two tight but a bit less. When you hammer the metal it stretches so the bottom two clamps will allow for the movement of metal. Tip - it helps to rub the metal with scotch brite so you can see your hammer marks.
Start hammering with a hard mallet. Go over the whole design. The design will start to show on the back of the metal. Now, take a polished ball peen hammer and start hammering in rows, being certain not to miss a spot. If the metal begins to buckle just flatten it out with the mallet, then keep hammering with the ball peen. Pay close attention to deeper spots in the die, you don't want to miss any deep areas with the hammer. If you miss a spot, the scotch brite surface will show where you missed. In this case, just re-hit that spot with the hammer.
When done, remove the clamps and see how you did. It takes a little practice, but works great.
Now just cut the metal to the shape you want, buff it, color it, buff a little more to get the color you want, form it and then shine it.
You can see my hammering set up on www.sga-sculpture-engraving.com
