#37 Fitting the Deckle to the Mould

The joints have been finished and now the four parts can be put together to form a rectangular ‘frame’. But the parts still need to be adjusted in a couple of ways to fit the mould before the joints are glued. In this post the the parts will be trimmed to create a small gapContinue reading “#37 Fitting the Deckle to the Mould”

#29 Copper Edge Strips and a few more details.

Copper shim stock .015″ thick makes good edge strips. These are needed to protect the edges of the laid and chain wires. But before the strips can be fastened in place there are a few more steps to be done. Bridge wires are inserted between the laid facing and the laid backing at both ends.Continue reading “#29 Copper Edge Strips and a few more details.”

#17 Finishing the Mould Frame

This post covers the remaining steps needed to prepare a double faced laid mould to receive its wire facing and backing. The topic of ledges and how they relate to backing wires in wove and laid moulds seems to need some explanation. It is important to understand the purpose of these structures so this postContinue reading “#17 Finishing the Mould Frame”

#16 Leveling the Ribs

The wooden structure of the mould is complete; now the tops of the ribs are scraped level in preparation for sewing down the wire facing. I like to pre-load the mould with weights before leveling the ribs. This gives the mould a very subtle camber; an extremely shallow arch in all directions. The forces ofContinue reading “#16 Leveling the Ribs”

#15 Pinning Ribs, Corners and Brace Rods

Metal pins are used to improve the connection between the parts of the mould. Holes are drilled and pins are driven down through the frame and rib pegs. These are made of 1/16″ unfluxed brazing rod that I bought from a welding supply house. Ribs are not glued and the pins make certain that theContinue reading “#15 Pinning Ribs, Corners and Brace Rods”

#14 Fitting Corner Braces

For these moulds both the braces and rub strips are made from polycarbonate sheet. To make rub strips narrow pieces are sawed and cut to length. Like the braces they are made slightly oversized and trimmed off later. Rub strips are attached with brass escutcheon pins. They are drilled in the same way that theContinue reading “#14 Fitting Corner Braces”

#13 Making Corner Braces

The bottom edges of paper moulds are often protected by the addition of corner braces and rub strips. Here is an ‘old style’ brace made of brass. You can see that this one was made by soldering two pieces together. The moulds I’m working on for this series of posts have braces and rub stripsContinue reading “#13 Making Corner Braces”

#12 Gluing Moulds

This mould has had epoxy applied to the corner joints and is secured with spring clamps while the glue cures. The dents left by the clamps poking into the wood will be covered by brass sheathing. Using clamping cauls eliminates the dents for moulds without sheathing. This mould is ready to glue and clamp. AtContinue reading “#12 Gluing Moulds”

#10 Assembling the Mould Frame and Ribs

The first step in putting a mould together involves only the ribs and the four pieces of the frame. Other parts; a brass brace rod and extra ribs called waterbars will follow. You may recall that one edge of each frame piece was intentionally left rough. This bottom edge is now smoothed by a singleContinue reading “#10 Assembling the Mould Frame and Ribs”

#8 Drilling Holes in the Frame to Support the Ribs

First Step: Dial In the Drill Press Table This drill press has a table that can be tilted and is prone to getting out of alignment. A dial indicator mounted in the chuck can be rotated by hand to check this. Small taps from a dead blow hammer are usually enough to correct misalignment. IfContinue reading “#8 Drilling Holes in the Frame to Support the Ribs”