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Making a press tool to make cross bands for scabbards
#1
I have been asked by a member on how to make the cross bands to hold the rings for scabbards. This a pic below Smile
   
The best way I have found to make them is using flat bar ect and sandwich the components together the only down side is I weld alll the pieces together to form a solid block. Otherwise you could drill through the parts and bolt together, if they dont line up then turnning the drill holes into slots you will have the room to line up the segments. Or if you are good with a file you can file away the profile. you then make a male punch with the same profile to press the pattern into the metal with a Thor hammer or similier so the punch stays true and does not mushroom. Hope you can keep up with me. I tend to make my cross bands out of heavier metal as in the past I have had scabbards come back for repair as the ring has worn through the band, this is what has happend on some origonals. If it is a simple profile then raising some of the plates up or as in the photo I filed the centre section for the two bumps then chanfered the outer plates to finish the edge. the male die I inserted a piece of stainless steel, to put the centre line in
I hope from the photos you can see how they are constructed;
   
This shows both tools with the brass being formed the left side shows a back plate this is a stop edge to run the material along so to keep it true as you hammer the pattern into the metal.
   
Now the profile shape needs to be made the width of the band you want the excess material can be cut from the length a bit fiddley but it means I can add a bit more width if I need too.
   
Once you have done the strip cut it back, you can run it along the die to crisp it up.
   
Sorry for the pic but I hope it shows other style cross bands and also the the profiles of the extra piece that the bands sit in.
 If you have any questions I will try to answer or if anyone would like to share there method please post Wink  As to the thickness of brass I will  will see what the calipers say but I just go by eye and intended purpose so you could use thinner if it was not holding any weight.
Woe Ye The Vanquished
                     Brennvs 390 BC
When you have all this why do you envy our mud huts
                     Caratacvs
Centvrio Brennivs COH I Dacorivm (Roma Antiqvia)
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#2
I thought a better view of this technique so went up to the Fabrica and expand  Smile
   
   
These show a better view of the profiles three are quite simple but I think you can with a little skill with file can produce most profiles for desired  effect.
   
This shows the start, you could cut the material down if you wish. The back stop will keep the material square and stop the lines wandering.
   
First pass.
   
Second pass.
   
Finally you can cut the excess away and crisp up the profile. Another thing i.e. when you make your press tool you need to take enough material away, to make allowance for the thickness of material you will use.
   
   
Finished piece plus the thickness of material used. Most tools I made are about 3" long but as you can see they can be made smaller. I hope this gives a better idea of the process, and you may think a lot of work for a job, but once done you have it for life Cool  you could buy a swage machine but expensive even second hand, plus you then need to make the roller dies for the profile.
   
This is what it looks like when put on the scabbard, running down the side is a strip I made from one of the other dies.
Regards Brennivs  Big Grin
Woe Ye The Vanquished
                     Brennvs 390 BC
When you have all this why do you envy our mud huts
                     Caratacvs
Centvrio Brennivs COH I Dacorivm (Roma Antiqvia)
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#3
Excellent tutorial. Thanks Tony.

Two questions.

Firstly, I notice in your third to last picture that one edge is turned up more than the other, but in your second to last picture both edges appear to be the same. Do you turn the piece around and repeat the process so as to get both edges the same?

Secondly, in your last picture you show the finished piece in place. How do you bend it around into the right shape without losing the profile produced by the formers. Am I correct in thinking that you anneal it and bend it by stages around a former, annealing again as necessary? Do you then temper it in any way?

Crispvs
Who is called \'\'Paul\'\' by no-one other than his wife, parents and brothers. :!: <img src="{SMILIES_PATH}/icon_exclaim.gif" alt=":!:" title="Exclamation" />:!:

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#4
Crispvs to answer your first question, it was less than five minutes to do and it is just the fact the tin snips on the left have flattened the end as it cut through it was the same on the opposite end which you cannot see. But I would first file and sand the edges before giving it a final run along to finish as you can see in the final photo along the edges nice and smooth.
To your second question I will show the tools I use to do the ring bends again very simple,  the brass I use old or new, 99% of the time I use no heat at all just my hands and a little help from a Thor hammer. The one in the photo is a Thracian locket type which is bent back on itself, the Mainz/Pompeii type the opposite. By putting in the profile on the brass it does not loose its shape when you bend it round a rod. So will post photos of the process.
Regards Brennivs  Big Grin
Woe Ye The Vanquished
                     Brennvs 390 BC
When you have all this why do you envy our mud huts
                     Caratacvs
Centvrio Brennivs COH I Dacorivm (Roma Antiqvia)
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#5
Crispvs heads up I have a window in my work so I will post my How Too on this one hopefully tomorrow   Smile I have a bit to do for the Hadrians Cavalry event. 
Regards Brennivs  Big Grin
Woe Ye The Vanquished
                     Brennvs 390 BC
When you have all this why do you envy our mud huts
                     Caratacvs
Centvrio Brennivs COH I Dacorivm (Roma Antiqvia)
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#6
Here goes pic heavy  Smile
               
First tools used as you can see basic, I made a small section of band out of 0.6mm brass old stuff. Used upvc window sil board as vice grips then filed the rough edges down to tolerance sanded edge and wire wool finish.
                           
Useing long nose pliers bend 90'. Place on round bar and useing hands start to bend, useing thumb slide it along brass as you bend this will keep it true and helps to stop kinking of the metal. Continue to bend until it is fully round the bar. To finish place bar and brass with angle iron in vice and as you can see gentley pull the brass together this will help pull the brass round to finish.
   
This is what you finish with, this is the type used on the Thracian type locket next your standered Mainz/Fullum, Pompeii.
     
Regards Brennivs  Big Grin

I have just used a standered scabbard for this this is best made when you have made your locket.
                           
Lie across scabbard and bend down and Mark were to bend, useing pliers bend 90' then place on bar and start to bend all the way  round. Useing pliers for the back, bend back to start the other side, then useing rod start the curve for to finish the rap around of the fit on the scabbard. 
               
As you can see it raps around the scabbard, both types side by side and finally the profile. I have just done this quick so a little bit more time you can refine the fit. Hope this helps you Crispvs and others and how basic tools and method is used  Smile  Wink
Regards Brennivs  Big Grin
Woe Ye The Vanquished
                     Brennvs 390 BC
When you have all this why do you envy our mud huts
                     Caratacvs
Centvrio Brennivs COH I Dacorivm (Roma Antiqvia)
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