TO MAKE A LETTER RACK
This is an easy problem. Only four constructive operations are required, viz., cutting out the stock, sawing the design, bending, and finishing. The illustration shows the form and the dimensions and suggests a simple design. The material required is 18-gauge soft copper.
Design for a letter rack
The first step in the process is to cut out a strip of copper 8 inches long and 4 inches wide. If necessary the edges may be trimmed even and then the round corners should be cut. The design is traced on strong, thin paper and securely pasted on the copper in the proper position by using cold liquid glue. A hole is drilled through each unit of the design by means of a hand drill, a jewellers' saw inserted, and the design cut. Time and patience will be required for this operation. Saws are easily broken, and new ones must be attached to the saw frame and again applied to the work. After sawing the design it is necessary to give the edges a smooth finish. This is done with a file. The surface which is to form the inside of the rack is then thoroughly cleaned and polished with water and pumice.
The copper is now ready to be bent to the required shape. To do this prepare a block of hard wood 8 inches long and 2 inches wide, grip it in a bench vise, and clamp the strip of copper squarely across the block in such a position that the sides may be bent over the edges of the block. When this has been done it only remains to clean the outside surface and finish it on the felt buffing wheel. If a fine polish is desired, the buffing should be preceded by careful grinding with a Scotch water stone and water.
TO MAKE A LETTER OPENER
This requires the same kind of material as the letter rack and the same operations, with the addition of riveting. After the stock is cut out, trimmed and trued up at the edges, an outline of the design is pasted on, as in the previous problem, and the design cut out. The top is then bent over and riveted with a copper tack, having shaped the head of the tack in the vise before inserting it. While the tack is being riveted the finished head should be protected by placing it on a lead block. Finally the edge should be filed to the shape shown in the cross section, and the whole cleaned and polished.
Design for a letter opener