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Post by Admin on Nov 20, 2013 9:21:09 GMT -5
 (16:43:03 ) [PIC] |..Exavier Exeter..| -[within a market shop]- says to ALL: I walk into the forge that I am renting, and reach into my pack, taking out a heavy book and laying it out onto the workbench, the cover, in filigree said, "Bronze Weaponsmithing ". I flip it open and begin to read a few pages to re familiarize myself with how the metal was forged. It had been a while since I'd had an order for something in bronze. (16:59:47 ) [PIC] |..Exavier Exeter..| -[within a market shop]- says to ALL: I have finished reading a few sections of the book and I put it away in my pack. I then undo my weapons harness and hang it on the wall, before stripping off my tunic and hanging that next to it. I yell to the thralls that work in the forge to get their asses up and start stoking and billowing the fire. They both come bumbling out of the small sleeping room next to the forge itself and get to work. I tell the one stoking the fires, I could not remember his name and it was not important, that I would need him to feed the fire a bit more slowly today. I was not going to need the same level of heat that I usually used with steel. I then turn to the work bench and take out another heavier pack that I brought with me today. There was some of the items from the blacksmith shop's contents I bought in the Inlet of Green Cliffs. The heavier things like the forge were being ported, but one of my men, Omega Stormreaver, brought me this pack that had a few of the molds in it, and some of the minerals and compounds I would need to cast bronze. Most of the metal of the spear would be made up of me creating molten bronze in the forge and then pouring it into the molds. Once that was done I would use a hammer and grinder to sharpen the edges. Fortunately I did have a mold with two spear heads, and then mold with two spear strikers in it. I would need to find the spear shafts somewhere else, so that the whole thing could be assembled. Taking three pouches out of the pack as well, one was filled with copper, one with tin and one with antimony. The copper and tin would mix together, and the antimony would work as a bonding agent for the other two minerals. I also took out a scale from the pack, as I would need to measure everything very closely. (17:10:49 ) [PIC] |..Exavier Exeter..| -[within a market shop]- says to ALL: I knew each spear head would weigh around one pound, and each striker would be close to half that. I therefore know that I need nine parts copper, one part tin and then a small amount of the antimony. I measure out the right weights, the copper and tin in nuggets that are poured out into the scale, checking the weights closely before dumping the copper, and then the tin into a pig iron ladle, that would end up being set in the fire. I then shave off some of the antimony, antimony is a mineral that flakes off much like obsidian would. I crush it up into a powder and then dump that into the ladle as well. Having the correct ratios of everything I look back to the thralls to see how they are coming with heating up the fire. I get dressed, pulling on my pock marked and heavy leather apron, tying it off at the nape of my neck and behind me. I then pull on the heavy gloves that I always used when working in the forge. I grab the end of the ladle and set the part that has the mineral blend into the coals of the fire. Seeing that the fire is just the right heat, I imagined that the man who owned this forge must work with bronze from time to time as the thralls knew what temperature the fire needed to be. I walk away for a moment, starting to set up the other items that I would need. (17:16:48 ) [PIC] |..Exavier Exeter..| -[within a market shop]- says to ALL: The smell of the tin and copper melting is interesting, and rather cloying as it fills my nostrils. It wafts up from the top of the ladle and drifts around the cloying heat of the forge. I can see the nuggets of copper melting, and then the tin as that had a bit higher level of heat at which it would melt. I use a small steel stirring rod to keep moving the mixture around in the ladle. It needed to be a perfect consistency for this to work. I then turn back to my work bench, starting to organize the vices that I needed. Each of the molds was two pieces of course, so it could be split apart at the end and the piece that had been smelted could be removed. I clamp the two sides of each of the molds together, two strikers and two spear heads in each. I turn back to the forge and see that the bronze is mixing nicely, I use another smaller ladle to scoop some of the imperfections out of the top of the mixture. I also check to be sure that the cold water bath is ready, with steel you use salt water, with copper it is tempered with normal water. (17:23:32 ) [PIC] |..Exavier Exeter..| -[within a market shop]- says to ALL: I turn back to the forge while the Scribe of Minus comes into the shop. The brass is finally mixed and ready to be poured, this would have to be done immediately so that I did not overcook it and burn the mixture. I scoop off the imperfections one more time, leaving me with a large ladle full of pure bronze. Grabbing the steel end of the ladle's handle I turn to the molds. Slowly and very carefully tipping the smoking hot ladle so that its pour spout lined up with the first mold. The top of the mold had two holes, one for each of the spear heads. I pour in slowly, filling the mold up until the molten metal is right even with the hole in the mold, and then move on to the next one. Stepping once to my left I line up with the mold that held the two strikers. I pour into the first hole, making sure that the bronze is still molten enough that it does not come out of the spout in gobs and ruin the work. I then move on to the other striker, pouring that one slowly. When I finish I realize that I have used almost all the bronze that I made. There is a small amount left and I pour it into a channel that will end up giving me a bronze sheet that I could use for other projects later. |
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Post by Admin on Nov 20, 2013 9:21:46 GMT -5
(18:15:26 )
[PIC]
|..Exavier Exeter..|
-[within a market shop]-
says to ALL: I smile as I turn back towards the interior of the forge, the thrall shuts the door and goes right back to the billows again as I approach the workbench. Undoing the vices from the molds I then set them down upon the surface of the work bench, using an awl and a hammer I knock both molds open and as the two sides fall apart I can see that the bronze was cast perfectly. There were some rough edges, where the bronze flowed just a bit into the crack between the two pieces of the mold, but beyond that they looked good. these minor imperfections would be fixed during the actual forging process and the grinding and sharpening process. I look at the two bronze spearheads, and I was sure that they were perfect, the mix had been just right. I then crack open the mold that has the two bronze strikers in it. They were just right as well, I could see the indentation in the mold that would allow for the spear shaft to be inserted into the striker. It would then be a matter of a few well placed strikes with the hammer to permanently affix the striker to the spear shaft. The spear heads would be attached with a rivet through the spear handle as they needed to be able to withstand much more stress.
The strikers were ready to go, they just needed some time on the grinding wheel and then the buffing wheel. On the other hand the spear heads needed to have their edges smoothed out so that they could be sharpened, and the point of the spear heads needed to be refined just a bit. I put on my heavy leather gloves again and then set the spear heads into the fire of the furnace. One of them goes directly into the hot coals, the other along the edge to start heating but not melt while I was working with the first one. One of these would be for striking, and one for throwing, but the spear heads themselves were identical, it would be the changes in the weight of the staff in the spear that would differentiate the two.
(18:20:41 )
|..Exavier Exeter..|
-[within a market shop]-
says to ALL: I set out the other tools that I would need, two hammers, not as big as the one that I wore at my belt all the time, as bronze was not as difficult to meld as steel, and did not need to be brought to the same temperatures. Usually with steel I was looking for a color somewhere between white hot and a yellow. With bronze, one wanted a orange red color, not nearly as hot. I see the first of the spear heads reach that temperature and I reach in with a set of tongs and pluck it from the heat that was irradiating the metal. There were waves around the bronze from the heat baking off it as I turn back to the anvil. I hold the spear head by the point right now, setting it down in an special indentation on the back side of the anvil, I then quickly clamp it in and take a steel punch. Using one of the hammers and the steel punch I drive a hole in the end of the spear that would end up going onto the shaft of the spear. I then unclamp it quickly and spin it around. Using the large hammer first to work out the fluttering edges of the spear head, and shape it down into what it would look like when completed. I then set that hammer to the side and take up another smaller one. Moving it quickly over the edge of the spear and up over the point I smooth the edges down, this would allow the spear tip to take an edge. This was done with great care, bits of bronze and sparks flying off each time the hammer strikes.
(18:23:53 )
|..Exavier Exeter..|
-[within a market shop]-
says to ALL: After I am sure that this spear head is done with what I can do with hammer and anvil I quench it in clear cool water, steam blasting up over my face as I do so, smearing some of the soot collected there. Sweat still runs down my shoulders and back as I wait for a moment, letting the bronze cool before pulling it back out of the fresh water bath and setting it on the workbench next to the two strikers.
I then move back to the furnace and push the other spear head down into the hottest part of the fire. This part of the fire was delineated by where the coals started turning to a fine white powder, this powder was pure carbon and burned the hottest. I wait for a few moments, one of the thralls working the billows and keeping the fire hot. When that reddish orange glow is attained again I use the set of tongs to remove the spear head. Again I go about punching the whole for the rivet, smoothing the edges with the first hammer and then starting to work a finer edge and a point with the other one.
(18:34:35 )
|..Exavier Exeter..|
-[within a market shop]-
says to ALL: I then quench the second spear head. Again the steam billows up from the barrel of fresh water. The steam collected in my hair, matting it to my back as it was held in a leather strap at the nape of my neck. Seemingly, if it was possible, the heat raised another degree or two as I finish working in the furnace. I finally tell the thralls to take a break, they both gratefully move out of the main part of the forge and into the small sleeping room that they had adjacent to it, they would probably rest and get some water, along with perhaps some bread or gruel, or whatever the owner of the forge I was renting fed them. With that I turn back to the four items on the workbench. Taking all of them up in my hands and walking over to the grinding wheel. This wheel was nearly the size of a wagon wheel but was made of solid whetstone. Along the bottom was a reservoir that collected oils that bathed the stone, so that the grinding would sharpen instead of just ruin the work I had already completed. I sit down, starting to pump the peddles on the wheel, and it begins to spin, slowly at first but then at a much higher rate of speed. I press the first of the strikers against it and sparks fly off of the bronze, coming to wash across my shoulders and the front of the apron I am wearing. I could feel them burning my skin just a little bit where they alight. I run the first striker around on the stone slowly, smoothing out any of the edges that were created by the smelting process, they would not shine yet of course, that would happen after I used the buffer on them. But when I was finished the first one looked like it would when I was done. I move on to the second one, working a bit more quickly, finishing that one and setting both of the strikers to the side.
(18:40:13 )
|..Exavier Exeter..|
-[within a market shop]-
says to ALL: I then take up the first of the spear heads, doing the same process I did on the strikers and smoothing out any imperfections in the bronze, but instead of setting them aside when I was done I started to drag the edge of the blades against the stone. Gently working each side of the spear tip and then the point at the end against the whetstone wheel. After a little while I could see that they were taking an edge, the spears would need to be sharpened on a regular basis though as bronze was not as rigid a material as steel is. I am working carefully, but relatively quickly to be sure that both of the spear heads are completed, and that they are perfectly sharpened. When I finish with them I use each to cut a hunk of leather, making sure that they are indeed razor sharp.
I get up from the whetstone wheel and move over to the buffing wheel. This one is the same type of stone wheel, but instead of being bare stone with oil it has leather wrapped around the stone. I begin to pump the peddles, getting it spinning even faster than the whetstone wheel. I start to work each of the strikers against the material surrounding the stone, it was then that the inner shine began to come out. It only took me a few moments to have each of the strikers looking perfect, and then I moved on to the spear heads.
(18:46:41 )
|..Exavier Exeter..|
-[within a market shop]-
says to ALL: I begin now to buff each of the bronze spear heads. Slowly working the metal against the buffing wheel. I was more careful with these, as I did not want to catch the razor sharp edge against the leather on the wheel and ruin it. I'd paid quite a bit to rent the place, and I did not want to have to pay to replace any of the equipment when I was done. I stand from the wheel and walk to the workbench, setting all the pieces in separate hunks of leather and wrapping them before sliding them into one of my packs. I would still need to find the shafts for the spears, but I did think there was a furniture maker who I could buy the raw materials from if I could not purchase the shafts whole. I would need two staffs approximately six feet along, one heavier than the other.
(11:19:37 )
[PIC]
|..Exavier Exeter..|
-[within a market shop]-
says to ALL: I knew that over where I was there were several places to acquire needed materials for warriors. Immediately next door to the forge was a small armory which should have the materials that I require for the shafts of the spears I am making for Cimber. After a bit of research I'd found exactly what I wanted as far as the spear shafts. The one for melee combat would need to be made of a sturdier and heavier wood, and the one for throwing would need to be made of a lighter and softer wood as it would often not be used for melee combat but would need to be the right balance and weighting to be thrown. I push open the door of the armory and walk inside. This huge bull of a man is standing behind the counter, "Tal, I am looking for two staffs, each six feet long, one made of temwood and one of kalana wood." He looks up from what he is working on, seeing me, a blacksmith and one of his fellow armorers and so he relaxes just a bit. He was huge, with a big thick neck and some of the same type of scarring that I carry on my massive form.
I walk over to one wall and see that there are several staffs there. I move to the area that has all of the six foot ones. Reaching out and taking up one of the black tem wood staffs. I run my hands against the smooth wood slowly, checking for any imperfections.
(11:29:40 )
[PIC]
|..Exavier Exeter..|
-[within a market shop]-
says to ALL: I look over at the owner of this shop, "So what would I be looking at in cost for this one?" I showed him the black temwood staff as I carried it over and set it on the counter. I allowed him to consider that for a few moments as I went back to the wall, moving to the area that had the lighter colored wood, selecting a six foot staff made from kalana wood. I look down the shaft, making sure it is straight, realizing that this one is not I put it back and select another one. This one does seem to be true, and has no imperfections so I set it on the table in front of him next to the temwood one.
"Aye, and how about this one as well." I say as he looks them over, his voice is low, and gravelly, kind of like two rocks grinding together, "Alright Smith, I could go as low as a silver for the pair of them." He says to me, and though that is a reasonably fair price I was going to be sure to haggle with him a bit, as that was what I always did.
(11:37:03 )
[PIC]
|..Exavier Exeter..|
-[within a market shop]-
says to ALL: I laugh at that offer, "By Odin I could buy a slave for that much coin, I am just a humble and poor blacksmith!" I look down at the two staffs, and recognize that they were both good quality and well made. "I could not go a copper over 25 for the lot." It was his turn to laugh, his deep baritone ringing out across the room again, "What, do you want me to just give these away Blacksmith!" He thinks about it for a moment, scratching his bearded chin, "I will not take a copper under 50 for the two staffs." He says, I recognize that it is a much better deal that someone would get walking in off the street, and I hoped to do business with him again so I nod, "aye, fifty copper will be agreeable with me as well."
I nod and reach into a small pouch in my weapons harness, dumping a bunch of copper coins out into my hand and counting through them until I reach 50. I pay him for the temwood and kalana wood staffs, "It was nice doing business with you." I say as I collect them and head back to the forge.
(11:48:04 )
[PIC]
|..Exavier Exeter..|
-[within a market shop]-
says to ALL: As I reach the forge I was renting again I went inside. I would not need the use of the fires today to finish the project I'd started with Cimber's spears. I had the spear heads and the strikers all ready to go. The striker would add about 3 inches to the staff, and the spear head would add about 9 inches to the staff, causing the total size of the spears to be almost exactly 7 feet. Before I was able to attach the striker and spear head though I would need to make a hole in the staff to place the rivet and attach the spear head, and I would merely need to hammer the striker to close the opening and attack it to the staff. Each piece when it was molded had the slot in it that would be the perfect size to push the staff in to. Some of the staff would go into each part, about three inches of the staff into the head, and with a 12 inch spear head this is how I would figure on adding the additional 9 inches to the spear's length, also about 2 inches of the staff would go down into the striker, the striker being five inches long would add three inches to the total length. All of this with the final product of a seven foot spear in mind.
(11:57:12 )
[PIC]
|..Exavier Exeter..|
-[within a market shop]-
says to ALL: I use clamps on the work bench to stabilize both of the staffs. Clamping them at both ends and then taking out a square that had measurements along one side of it, and a charcoal pencil. I mark off where I want to drill the whole in the end of both of the staffs to permanently affix the spear head, or well affix it until the staff broke at some point, they would both be durable but it was not impossible to break a spear. Using a rotary crank hand held drill I carefully drill both holes. They would be the perfect size for the rivet to slide through.
After drilling the holes I use a little bit of sand paper to smooth out the edges and then unclamp the staffs from the vices on the bench. I take out my pack that I carry everywhere with all my work in it, and take out a few pieces wrapped in leather. The two spear heads and strikers, made of bronze and buffed to a deadly gleam. Carefully unrolling each of the leather wrappings and setting everything out on the bench. I start with the kalana wood staff, sliding the spear head over the end of the staff, and lining up the hole. I then take out a rivet and slide it in, making sure everything is lined up just right. Reaching to my left I select a small hammer and bring it over, one hard strike against the rivet on each side expands it in the hole, affixing the spear head to the staff.
I then move on to the other end of the staff, sliding the striker in place, and turning it so that it is just right. I then bring the same hammer down against the edge of the striker, all the way around, sinking the bronze into the wood and permanently attaching the striker to the staff. Well it now was a spear, a completed throwing spear.
(12:08:29 )
[PIC]
|..Exavier Exeter..|
-[within a market shop]-
says to ALL: I move on to the other spear, a bit excited as I could see that this project was coming to an end. I wanted to present these to Cimber soon, and also find out if he was interested in me catching up with that jeweler again to have the heads engraved with anything. The temwood is a much harder and heavier wood, perfect for melee combat. Again I slide the spear head on, and insert the rivet, hitting it with the hammer on both sides. I then attach the striker in the same way I did before, for the edge of the striker to bite into the wood on the temwood though I had to hit it much harder. I was careful not to deform the striker or the edge of the striker with my efforts though. I then took up the kalana wood spear, and hefted it, and held it over my shoulder. It was comfortable, from my research I found that there were no wrappings or handles on the spears. The kalana wood should have enough texture to it that it would be easily gripped, even by sweaty hands. I set the kalana wood spear down and take up the temwood one, spinning it expertly and thrusting in a few different directions, making sure it was properly balanced and felt good in the hand. I decided that they were done, and I hoped that Cimber would like them and be able to use them.
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