Steps to Make a Dancing Shapes Design
- Cut copper – four 24 x 24
- Mark lines for brass spirals x 2
- Melt on brass spirals
- Patinate – salt/fire, then rinse & dry
- Soak off white flux, then re-rinse & dry
- Scratch clean backs – wash & dry
- Prime backs x 4 – dry 2-3 days
- Prep marine plywood – cut & varnish
- Prep dowel for risers – black primer
- Glue copper to marine plywood – one sides
- Trim off excess wood
- Glue on copper backs
- Clean glue off front as needed
- Spray on varnish
- Wax front & back
- Mark lines for cutting
- Cut squares & circles
- Sand squares & circles
- Repair gluing as needed & fill holes
- Re-sand as needed
- First edge coat – black primer
- Second edge coat – eggshell black
- Clean back with 3M pad on grinder
- Debur front edges
- Layout mylar & mark dimensions
- Mark all pieces – workout actual design
- Cut risers from dowel
- Sand rough edges from risers
- Eggshell black on risers
- Test design layout with risers – cut more as needed
- Trace design onto front with red marker
- Flip mylar
- Exact trace all pieces onto mylar – upside down – use fine point marker – mark all ‘ups’ – mark register
- line for circles
- Exact trace all pieces onto other overlapping pieces – use ruler, etc.
- Do upside down layout with risers – mark all B’s, all U’s, all +’s
- Attach all +3’s, +5’s and +7’s with ¼” dowel and glue
- Drill ¼” holes in centers of all +1’s
- Drill 1/16” holes in all U’s – do a complete layout and peg with 1/16” brass tig rod
- If good, drill all holes 7/64”, counter sink tops, use 1-5/8” screws to assemble, peg all singles
- Using wax, clean off all black marks on back and front
- Remove tape
- Touch up edge blacking as needed
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