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.
[Illustration: 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.