HO Studley

A Tale of Fun With Hefty Silver Soldering – Infill Mallet 1


Of all the tools I’ve encountered that have seduced me Henry Studley’s infill mallet ranks at the top of the list.  To continue the unenviable task of keeping my probably ADD self amused I decided to play with making something similar, a project I could work on intermittently while some glue or paint was drying, or when I needed a distraction while I cogitate.  For the raw material I ordered 1/4″ wall thickness right-angle brass stock from McMaster Carr to serve as my starting point.  Since this was more a “proof of concept” exercise, the concept being proven being the silver soldering of very heavy stock, it seemed like a sensible approach.  Perhaps for a “proof of concept” exercise I should have started with aluminum rather than brass, but that’s where I started nevertheless.

With the measurements in-hand I chopped the requisite segments and set up a soldering set-up on my heat-work station (I think I will probably write a series of posts about setting up such a work station yourself as I hope you will all follow me down this rabbit trail).  My strategy was to simply overlap the two sections with each other as shown and fire up the torch.  Even though I could/would only do one seam at a time I slathered generous dollops of paste flux on both interfacial surfaces.

After heating the entire mass I concentrated on the seam joint and introduced the silver solder on the inside corner of the seam and let the torch heat draw the solder through the joint.

It worked perfectly.

Stay tuned.