Re: Help in Making Medallions?
Drew Hagemann (hagemann@VISI.NET)
Fri, 17 Oct 1997 17:12:45 -0400
Richard Seymour wrote:
> Has anyone ever considered making hiking staff medallions themselves to
> commemorate Troop events or individual achievements? How do you do it?
> What sort of metal-working skills are involved? Is there a photographic or
> copy shop alternative that can be laminated and attached to a hiking staff
> somehow? Any ideas?
You have struck pay dirt here. My Metal Work MB staff and I came up
with a simple way to make stamped metal hiking staff medallions for '97
Here's what you do:
METAL DISK: Have a machine shop make (and donate) punched metal slugs,
about 1.5 inches in diameter, using 0.0050 (fifty-thousandths) of an
inch thick sheet aluminum.
BOTTOM SWEDGE BLOCK: Take a 4x4 inch stud and cut off four inches to
use as a home-made swedge block. To make the swedge block, gouge a
straight, 0.75 inch diameter groove down the length of the block, right
down the center. Carefully sand the groove smooth; do not apply any
finish coat since it will soon be ruined anyway.
TOP FULLER: For the top fuller (the piece that will press the curve
into the disk) obtain 6.0 inch piece of 0.75 inch (outside diameter)
heavy walled pipe. Carefully sand the pipe smooth. Remember, since
aluminum is a soft metal, any imperfections in the bottom swedge or the
top fuller will appear in the swedged medallion.
Using 0.25 inch letter stamps or a custom made single-piece 0.5-inch
metal stamp of your own design (as a reference point, a 1 inch diameter
two-piece stamp that will produce a complex, coin-like design will cost
about $200), stamp the design into the aluminum disk. Drill two small
holes in the top and bottom outside edge of the medallion for attaching
it to the hiking staff with small screws or nails. Do this before you
swedge (put the curve into) the aluminum disk.
Clamp the bottom swedge into a vise, resting the bottom of the wood
block against the vise's screw for added purchase. Place the aluminum
disk across the groove, centering it along the groove, mounting holes
running either "east and west" or "north and south" (your option).
Place the 0.75 inch pipe in line with the groove, resting on the back
side of the disk. With a single, firm blow to the pipe (use a 24-oz.
ball pien hammer to make sure the blow is hard enough), press the disk
into the groove.
Presto - one custom made hiking staff medallion.
If you decide not to make a metal stamp, buy several 0.25 inch letter
stamp kit and let the Scouts go to town with their own messages. Oh,
yeah. Be sure to hold each stamp with a pair of good vise grip pliers
before striking them with the hammer. If you don't, an angled hammer
blow will send the stamp flying off like a bullet, and the offending
Scout will probably mash his thumb to boot. And anyone in front of the
flying stamp will be seriously hurt. Trust me on this, please!
Write for more info or clarifications.
Andrew Hagemann <firstname.lastname@example.org>
SA, Troop 6
Colonial Virginia Council
A "Charging" Buffalo, SR-158
Jamboree '97 Metal Work MB Booth Coordinator
Terry Howerton Sakima Group, Inc. SCOUTER Magazine Kansas City