The quantity of the finer emeries consumed in smoothing a 15 1/2 inch surface is very trifling—a mass of each as large as two peas sufficing.
Rouge, or peroxide of iron, is better bought than prepared by the amateur. It is made by calcining sulphate of iron and washing the product in water. Three kinds are usually found in commerce: a very coarse variety containing the largest percentage of the cutting black oxide of iron, which will scratch glass like quartz; a very fine variety which can hardly polish glass, but is suitable for silver films; and one intermediate. Trial of several boxes is the best method of procuring that which is desired.
c. Tools of Iron, Lead, and Pitch.
In making a mirror, one of the first steps is to describe upon two stout sheets of brass or iron, arcs of a circle with a radius equal to twice the desired focal length, and to secure, by filing and grinding them together, a concave and convex gauge. When the radius bar is very long, it may be hung against the side of a house. By the assistance of these templets, the convex tools of lead and iron and the concave surface of the mirror are made parts of a sphere of proper diameter.
The excavation of a large flat disc of glass to a concave is best accomplished by means of a thick plate of lead, cast considerably more convex than the gauge. The central parts wear away very quickly, and when they become too flat must be made convex again by striking the lead on the back with a hammer. The glass is thus caused gradually to approach the right concavity. Ten or twelve hours usually suffice to complete this stage. The progress of the excavating is tested sufficiently well by setting the convex gauge on a diameter of the mirror, and observing how many slips of paper of a definite thickness will pass under the centre or edge, as the case may be. This avoids the necessity of a spherometer. The thickness of paper is found correctly enough by measuring a half ream, and dividing by the number of sheets. In this manner differences in the versed sine of a thousandth of an inch may be appreciated, and a close enough approximation to the desired focal length reached—the precision required in achromatics not being needed. The preparation of the iron tools on which the grinding is to be finished is very laborious where personal exertion is used. They require to be cast thin in order that they may be easily handled, and hence cannot be turned with very great exactness.
The pair for my large mirrors are 15 1/2 inches in diameter, and were cast 3/8 of an inch thick, being strengthened however on the back by eight ribs 3/4 of an inch high, radiating from a solid centre two inches in diameter (a, Fig. 6). They weighed 25 pounds apiece. Four ears, with a tapped hole in each, project at equal distances round the edge, and serve either as a means of attachment for a counterpoise lever, or as handles.
Fig. 6.
The Iron Grinder.
After these were turned and taken off the lathe chuck, they were found to be somewhat sprung, and had to be scraped and ground in the machine for a week before fitting properly. The slowness in grinding results from the emery becoming imbedded in the iron, and forming a surface as hard as adamant.