Project 4: Gouge Patterned Pin
Carving and Forging Techniques to Create an Attractive Brooch
Gouge Patterned Pin. Sterling silver with silver and nickel-silver mokume.
Photo 1. Begin carving the initial design in a 1/4-inch (6mm) thick mokume billet. Use a flexible-shaft machine with a fast cutting bur. The one pictured here is a 12mm 90-degree bearing bur. Your deepest cuts should go about a third of the way through the billet. Try to avoid deep cuts that go all the way to the edge of the billet.
Photo 2. Before you begin forging, use a smaller 2- or 3-mm ball bur to round out the bottom of the carved cuts. This prevents localized cracking caused by the stress focused here when it’s forged. Proceed to forge the piece until the entire surface is once again level. Anneal frequently.
Photo 3. Begin your second course of carving. Once more carve to a depth equal to one third the thickness of the billet. The design from your first course will be visible and you have quiet a bit of control now to enhance it. You may stop carving and quickly patinate the billet at any time to make the new pattern you are cutting more visible.
Photo 4. Forge again as in step 2. Your final hammer work should be to planish the piece lightly and level the marks from forging to achieve a uniform thickness. Then file smooth with a fine-cut file.
Photo 5. Roll the piece through a rolling mill to elongate and expand the design until it is about 22 gauge in thickness. If you have thin spots on the edges of the billet they will sometimes crack as the piece is rolled. If this is a problem, trim back the edge, or add to its thickness by melting a little solder on the back.
Photo 6. Cut and file the piece to its final round shape and then lightly dome it to give it more dimension. Sand with 400-grit paper, then set aside while you prepare the silver trim wire.
Photo 7. Use 14-gauge square wire and construct a round trim band to the exact size of the mokume piece. Solder with hard solder, pickle and then remove any excess solder by filing.
Photo 8. Press the domed mokume piece into the trim band. If you’ve measured right, it should hold without binding wire. Flux the entire piece generously, and then, from the backside, solder the trim band in place. Remember to solder the area near the solder joint in the trim band last. After this, carefully solder on the pin findings with easy solder.
Photo 9. The finished Gouge Patterned Pin has been acid-etched to enhance the texture of the mokume and hand-polished with fine steel wool. Sterling silver with silver and nickel-silver mokume.
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