JIM HARMAN

Saddle silver created using a hydraulic press.

Custom Saddle Silver
by Jim Harman
http://www.saddlesilver.com

The following is a description of the fabrication and die forming of the swell plates. (The pieces just below the saddle horn--see second photo below). These swell plates were fabricated from sterling sheet and wire. Each piece consists of four elements: the back plate, the border, the star and a row of beads. These elements were soldered together before forming. As these pieces fit compound curves, male pushers are required.

STEP ONE: Isolate the area on the saddle swell where the piece will eventually be attached. This was done with sculptors modeling clay.

STEP TWO: Fill the dam with plaster of paris to a depth of one inch. Let plaster dry.

STEP THREE: Remove clay and plaster. The plaster block is a negative form of the steel pusher to be made. A clay wall is built around the plaster block with the negative molded side up.

STEP FOUR: Using liquid steel, fill the dam to a depth of about one inch. Let cure for 24 hours. The resulting steel block is now the positive male pusher used to form the silver plates. The pusher is taped to the top platen of the press. The silver, finished side against the urethane, is placed in the Forming Box. These pieces were formed at 6000 lbs. of pressure.