Garden Whistle Apr 2012 - Sandman.org.nz

The Garden Whistle - April 2012
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Soldering it all together
A jig was made by taking a small block of wood.
Into this was drilled a 1/8 hole into which was inserted
a short length of 1/8 dowel .
The buffer face is placed over the dowel to rest on the
block of wood.
Then place over this ,the hollow rectangle with the
partly cut away and trimmed off square, check that all
is arranged okay. Solder it all together with a hot iron.
The wood will burn , avoid using MDF for the jig
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Once soldered the buffer head was roughly trimmed
off, then filed to give it some shape .
The 1/8 square bar had a slot cut into it, once again to
allow space to get a file in.
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To ease the soldering ,and stop the assembly falling apart
when heated, small balls of wet tissue paper can be placed
around delicate parts to act as a heat sink, and keep parts
in place
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The peg was changed in the
jig to a much shorter one.
The formed head was then
placed back on the jig. The
slotted 1/8 bar was the fed
into the head
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B
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and pushed in to the face. The assembly was then
checked for squareness . All was soldered in place
with a hot iron .This forms the shank.
To replicate mid production buffers ,a gusset was required.
(Choose which is to be the top)
For this the 3/32 x 1/32 strip was used. One end is
filed square to fit then soldered in place ,the step is
then repeated for the gusset on the other side.
These were trimmed and filed to shape later when
satisfied they were in the correct place.
( this part of the exercise can be frustrating as parts
may want to let go ,use of a heat sink and patience
was required ,it all works out in the end)
A strip op 3/32 x 1/32 strip was soldered to the bottom
of the buffer head, two holes of 1mm were then
drilled in it to provide a location for the bridle to fit.
The ‘U’ was then cut out of the face and shaped.
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