Hammered Copper Bell
Work done using the TM Tech Air Power Hammer

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  • Hammered Copper Bell

    Metal selection

    24 oz. copper sheet was selected for the job.

  • Hammered Copper Bell

    Cutting

    Each flat copper blanks was cut to the correct size and deburred before hammering the shape into them.

  • Hammered Copper Bell

    Tool selection

    Luckily Joe already owned a TM Technologies Air Power Hammer, which was the ideal tool to hammer up all of the skins.

  • Hammered Copper Bell

    Die selection

    The Air Power Hammer was set up with Large Reverse Dies to make the reversed shapes needed for the Bell.

  • Hammered Copper Bell

    Working out the curves

    Each panel or skin was carefully hammered to fit the steel frame.

  • Hammered Copper Bell

    Tweaking with the bag and spoon

    When you get a little frisky with the stretching you have to get the bag and spoon and shrink it back down (or put a set of Lancaster jaws in the press brake).

  • Hammered Copper Bell

    Fitting

    Joe and John check the fit of every panel to make sure they fit the frame and also all of the adjoining panels.

  • Hammered Copper Bell

    Working out the contours

    Each course of the three courses was made, and curved templates (not shown) were used to confirm the contours.

  • Hammered Copper Bell

    Second course

    The second course was made in turn.

  • Hammered Copper Bell

    More shaping and fitting

    And the courses were checked against each other.

  • Hammered Copper Bell

    Fastening

    Cleco spring fasteners and big clamps were used to hold the skins until rivets were used permanently.

  • Hammered Copper Bell

    Offsetting the skins

    The edges of the skins were offset or joggled so the skins fit very closely, as the whole Bell was carefully shaped to look as one piece from a distance.

  • Hammered Copper Bell

    Almost done

    Joe’s big smile means we are home free: on budget, great fits, and wonderful contours. This entire reverse shape was made with the TM Technologies Air Power Hammer.

  • Hammered Copper Bell

    Installation

    Here is the completed job after installation.