Project by Elizabeth M. Meadows from Oberlin, Ohio.
Elizabeth has little time for herself. Not only does she help her husband run his stone-carving business, but she also chases around three wild little boys. In addition, this down-to earth mother found a way to incorporate metal sculpting into her life. Although her metal garden sculptures may take months to complete because of her schedule, she has found a nice "word-of-mouth" niche in her supportive community.
Materials:
5" x 5" 16-ounce copper sheet
15" to 20" x 1" 16-ounce copper sheet
1-1/4 x 1/16" thick scrap brass sheet
oxygen acetylene torch
1/8" diameter steel rod
1/16", 3/16" steel welding rod
low-temperature brazing rod with 5 % silver
coated bronze brazing rod
clamps/grips/locking pliers
metal sheers
metal pliers
rawhide mallet
chasing hammer or ball-peen hammer
Steps:
1. Cut a 5" x 5" square out of a copper sheet.
2. Draw a circle in the center of the square leaving approximately 1-1/2 inch on the sides.
3. Draw triangles on all the way around the rim of the circle. Start cutting around the outline of which will leave the circle with pointed edges. The finished piece will resemble a star. This will be considered the sunflower head.
4. File the edges with a flat file until smooth. Use sandpaper as needed.
5. Create the flower head by hammering from the back of the copper onto a sandbag or wooden stump with ball-peen hammer or chasing hammer. Hammer until metal gets stiff.
6. Using an oxygen acetylene torch, heat (anneal) the metal until it glows a deep red color. Hold piece with a pair of metal pliers. Dip in water to cool. Repeat hammering until pleased with the shape of the flower head.
7. Cut out nine to 11 brass petals, 3 to 5 inches long each. One end should have a rectangular 3/4-inch-long tail for attachment, while the other end should be tapered with a rounded tip. File and sand all edges. Place petals around the flower head to confirm that there are enough petals to surround the head evenly.
8. Hammer a vein into each petal by placing a 1/16-inch steel rod on the brass and hammering along the rod to make an impression.
9. Fold the rectangular end of the petal back 90 degrees. Clamp the petal to a spot in between two of the pointed copper triangles on the flower head.
10. One at a time you will need to braze (with the torch and low-temperature brazing rod) all of the petals onto the flower head.
11. Fold all of the petals back, adjusting as necessary with smooth needle nose pliers.
12. Heat the petals with a torch and dip into water to color the petals. Keep the torch lit and color all of the petals in one sitting to get consistent coloring results.
13. Attach the back of flower head to a 1/8-inch-thick steel rod (this will be the stem) using a torch with coated bronze brazing rod.
14. Cut out one copper leaf approximately 15 to 20 inches long by 1 inch wide, tapering to a rounded edge at both ends. Cut, file and sand down center of leaf to about a 1/2-inch width.
15. Make a vein line with another piece of 3/16-inch steel welding rod by hammering down the length of the copper, avoiding the central 3 inches of the leaf.
16. Place center of leaf on steel stem and wrap around the stem tightly and clamp with locking tweezers. Braze the leaf to the stem with the torch and low temperature braze.
17. Hammer the stem with a rawhide mallet to work harden (stiffen).
18. Use files and sandpaper to remove excess braze from around the stem and leaf.
19. Adjust the petals and leaves until it pleases you. Hammer with rawhide mallet to work harden.
20. Use steel wool to polish the raised surface of the flower head.
21. Plant it outside in the garden and train morning glories or other vines to grow up it.
Website: http://home.ix.netcom.com/~fairplay/index.html
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