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Load the acrylic dies in the bottom of the box, making
sure that there are no overhanging areas. Place the
smallest die opening at the bottom of the stack. Place
the Kevlar die plate on top of the acrylic. Typical
thickness of the stack for the 3" box will be 1/2" to
1-1/4". For the 6" and 6x12 boxes, it will be 1-1/2"
to 2". Place fully annealed metal on top of the Kevlar.
Do not use any lubricant at this time. Place the two
60 durometer pads on top of the metal. Close the box
using the pusher supplied (for the 6" square box, use
the top spacer as the pusher). First pressing should
be to about 4000 pounds per square inch (psi).These
pressures are based on using a 20 ton press! Lower pressures
are appropriate for larger presses. Remove the metal
and anneal. The metal in the 6" and 6x12 box can usually
handle larger pressures, as the die opening is larger.
Place the annealed metal back into the box, and place
a small amount of lubricant in the recessed area. Stay
away from the flange area! Lightly lubricate the area
between the two pads, and press again to the same pressure.
For the third and subsequent pressings, place the 60
durometer pad on the metal and build-up a small stack
of intensifiers, (approximately 1/2" to 3/4" high) over
the area that you want to move the greatest amount.
Put a small amount of lubricant down into the metal
cavity, and a bit more between the two pads, and a bit
more on the bottom of the pusher. Remember... a little
goes a long way. Place the remainder of the pads on
top of the intensifier stack, and press again. By now,
the form should be taking quite a bit of shape. Additional
annealings and increasing the height of the intensifiers,
moving the pyramid around as desired, will enable you
to get some really deep forms very quickly.
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