After being sawed, the slab of gem material is examined, and the location and size of the stones to be cut from the slab are determined. The desired outline of the shape of the gem to be cut is marked on the slab with a pointed piece of aluminum rod; ordinary pencil marks are not used because they wear away too quickly in the cutting process. Once the area from which the gem is to be cut has been selected and the outline of the gemstone has been marked on the slab, the excess material is trimmed away by a smaller diamond saw known as a trim-saw. In some slabs the excess material can be broken and “nibbled” away with a strong pair of pliers.
The remaining portion of the stone is usually held by hand and ground to the desired shape using the previously scribed mark as a guide. This is done using a relatively coarse-grained (about 150 grit) specially made carborundum grinding wheel.
Now that the desired outline has been obtained, the stone is firmly affixed to a slender wooden or hollow aluminum dop-stick ([fig. 4]). The process whereby the stone is attached to the dop-stick with a specially compounded jeweler’s wax is called dopping. The dop-wax is heated over an alcohol lamp or candle flame until it is soft and pliable and is then spread around on the end of the dop-stick and formed into a mass about the right size and shape to fit the back of the gemstone. The stone is likewise heated, and the wax is applied to the back of the stone while both wax and stone are hot. Upon cooling, the wax firmly fixes the stone to the dop-stick. The dop-stick allows the lapidary to have firm control of the stone during all later stages of cutting and polishing.
Fig. 4. Cabochon properly attached to dop-stick.
CABOCHON DOP-WAX DOP-STICK
The top of the dopped gemstone is worked against the coarse carborundum grinding wheel until it is a rough approximation of the desired shape. The stone is then worked against a much finer-grained (about 220 grit) grinding wheel to remove the irregularities left by the coarse grinding and to further smooth and shape the surface of the gemstone. At all times while grinding, a small flow of water should be directed on the grinding wheel to keep the stone cool. Grinding on the stone for even a few minutes without cooling may result in the shattering of the gemstone because of heat created by friction of the stone against the grinding wheel. If the lapidary keeps the surface of the grinding wheel wet, there is little chance of damaging most gem materials.
The next phase of cabochon cutting and polishing is sanding. The gemstone is worked against two sanding drums of different grit size. This sanding can be done with the sandpaper surface either wet or dry, as needed or as preferred by the lapidary. However, great care should be exercised during sanding so that the stone is not overheated. Overheating can easily occur whether the sandpaper is used wet or dry. As in grinding, sanding is first done on coarser grit paper (about 300 grit) and last on finer paper (about 600 grit). It is in the sanding process that the first hint of polish is noted on the surface of the stone. After sanding, the gemstone should have perfect form with no surface irregularities, a very finely textured surface, and only very minor scratches left from sanding. The gemstone is now ready to be polished.
Fig. 5. Cabochons at various stages of cutting and polishing. Left to right: trimmed from slab: ground to outline; after rough grinding; after sanding; polished.