Using tiny gauge electrical wires to make a Habaki.

T

Tset Tsyung

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Apr 14, 2014
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Hey all,

I'm working on a Tanto that I'm making using the stock removal method. This build is going to be the most complicated one I've done so far (previous are 3 piece - blade, scales, bolts), but I've tried doing a little forging for the Habaki.

I've taken stripped electrical wires and tried hammering them into a billet that I could make my habaki from. However, all I've ended up with so far is a grey brittle mess! Copper Oxide being the culprit.

At first I was able to make a small billet, and this was fine. But then when I tried to fold it and add more copper it just wouldn't weld and would fall apart. So my question is this:

Is there a flux that I can used with such small wires? If not could I try putting them into a stainless foil envelop (airtight), heat them up and then hit them a bit to get the basic billets and work from there? (Yes I know this would be 'working blind'.)

Of course, casting is an option... but don't know if it's one I'm happy doing in my tiny garden... Should I just abandon such 'recycling' ideas?

Many thanks for your input and time Ladies and Gentlemen!

Mike
 
Perhaps even cold forging them so that they are tightly packed and then hot forging to weld them together?
 
Several problems here:
First, electrical wire isn't pure copper. It would probably be very poor to try to forge weld.
Second, forge welding many tiny pieces of metal together is a poor way to get a bulk mass. Melting and casting a blank billet, then forging that out would be a much better way if you only had the wire to work with.

The flux for things like copper and silver is something like 90% borax, 5% boric acid, and 5% powdered charcoal.



It would be far simpler and would yield a better product to use sheet copper. Soaked in Livers of Sulfur for 15 minutes or so and then lightly buffed or brass brushed, a completed copper habaki looks like ancient shakudo.



If desiring some sort of neat pattern in the metal, try something like this:
Take 12-14 gauge annealed wires of copper, silver, and brass. Using seven strands, twist them as tight as you can ( tip - fuse the ends first). Anneal, pickle, and twist again. Using 1400F hard silver solder, solder the bundle completely ( don't worry too much about extra solder). Forge flat, annealing often and carefully so as not to unsolder, until it is a long flat strip. Cut into 3" pieces, stack and solder together. Forge out into a sheet and make the habaki using 1100F easy silver solder. This isn't too hard to do, but will take some skill. The resultant twist mokume looks pretty good.
 
Stacy - you are amazing!

Thank you so much for all your help, not just on this post but my others as well. Was looking to order some sheet copper. But came across Mokume/Mokume Gane and thought I might try that as well! THANKS! XD
 
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