All of the pieces to this brooch have been made and now it’s time to assemble everything together. I will do so by soldering them in place. The cast center section is an important part of the design not only in form but also in function. It acts as a central visual color compliment to the Ammolite and also structurally holds everything together and strengthens the brooch.
Polishing Components First I must polish the entire piece while it is separate allowing easy access to areas that will be difficult to clean once it is attached.
Soldering Center You will notice at this stage I no longer have the temporary bars connecting the two halves. They were only needed to form my cast piece. They have been cut away. I solder this from the back. Notice the two tabs on each side of this cast piece. I carved those in the wax because I knew I would need an area to solder and secure the two side elements. The white area is a flux that keeps the metal clean during soldering.
Soldering Center I have heated the piece and the flux has turned glassy preventing the solder area from oxidizing. If you look very close you will see small round beads of solder surrounding the two tabs. Everything is in place ready to put the torch to it.
Adding heat to solder Heating the entire pin with the torch to bring it to temperature so the solder will run. I need to be careful not to heat it too much or else I run the risk of melting other components. This is a very critical operation and close attention must be given to all the components in play: The position of the side pieces, the position of the center section has not turned or moved, the placement of all the solder, heating all of these pieces equally so they reach temperature at the same time (if one section is cold the solder will not run into the seam), not over heating so the tail does not “un-solder” and break off, or worse… overheating and burning a hole or melting the back of the side pieces.
Unfinished Brooch It’s necessary to flip the piece over and examine the front to be certain it is aligned properly. Sometimes it all looks good from the back and when seeing it from the front something is out of line. It is a terrible thing when you have to take all your work apart and redo it… experiencing the same difficulties and risks. Fortunately it all looks great!
Solder Complete Notice the round solder beads are gone and melted into the seam. Success!
Soaking in the pickle Placing the pin in a pickle bath (warm acid to remove the flux and oxidation)
