[Jewelry making - Article 00162] - Re: [Orchid] Flatware filler

[Ian W. Wright]

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    There have been a number of suggestions from various people as to
    possible fillers for these handles, some of which would do the job
    but many of which would not be a very satisfactorylong-term solution.
    I wouldn't say that the advice I gave in this case of using pitch or
    wax and a stone dust filler, is necessarily the only way or even
    perhaps the best way to do the job as new materials are always coming
    along which may just supplant the traditional materials. However, I
    only post advice on things I have some personal experience of and on
    which I think I understand the reason for traditionally doing things
    that way. In this case, of course, the filler has to be stout enough
    to support the handle against quite rough knocks and strong enough to
    hold the blade tang in firmly and withstand regular washing in hot,
    detergent filled water. In the past, the silver or gold handles of
    fine cutlery were the most expensive part and it was not uncommon for
    the gentry who could afford such luxurious cutlery, to have broken or
    sharpened away blades replaced in the original handles - thus it was
    necessary that the filler material should be able to be softened just
    enough to remove the old blade without damaging the handle.
    Additionally, there is always the possibility that the blade will
    become loose in the handle through heavy use or through being dropped
    and it would be very difficult to remove some of the 'permanent'
    fillers which other list members have suggested. In the old days of
    course, cutlery was produced by many small firms which operated on
    the 'Little Mesters' principal - the cutler would commission blades
    from the forger who would pass them on to the grinder who would pass
    them on to the hardener who would pass them on to the finisher who
    would pass them on to the mirror polisher who would pass them on to
    the handle fitter from where they would eventually arrive at the
    cutler and the packer. All these various trades people were self
    employed and worked either from home or in workshops rented often
    from the cutler. They were usually kept fully employed by the one
    cutler but may sometimes have worked for two or even more cutlers.
    So, each handle maker and fitter had their own 'secret recipe' for
    the handle filler as there was no standardised material commercially
    available. However, most of the makers seem to have used virtually
    the same basic materials - maybe some would have added a bit of
    beeswax to make it easier to put in the handle in the first place,
    some used brick dust, some limestone dust, some sand and most used a
    mixture of more than one of these. It is unfortunate when people use
    materials such as epoxy just because it is there and it says on the
    packet that it will do everything - more often than not it won't!
    There were many, many years of thought put into the old time choices
    of materials and very sound practical and scientific reasons for the
    way things were done. 

    Whatever you do decide to use, you must ask yourself a few basic
    questions - 

    1. will the material hold the blade securely for many years? 

    2. can it be used to fill the handle completely - i.e. does it
    shrink as it dries and can it be packed into every corner and
    crevice? 

    3. is it strong enough to support the handle shell? 

    4. if there is a problem filling the handle or if the blade
    subsequently needs to be removed can this be done and, perhaps more
    importantly, can the filler be removed from the handle without
    damaging it? 

    5. will the filler stand up to everyday use? Unless you are going to
    do research and experiment on all these points, 

    I would stick with traditional materials - we know they work... 

Best wishes,
Ian
Ian W. Wright
from the home of the finest cutlery - SHEFFIELD UK
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