Thursday, 25 October 2018

Brass bowler hats

These are used to cover the ends of the swing irons where they poke through the hoof rail. I suspect Zaphod didn't have them originally, as I can't find any screw/tack marks, but split pins and washers look a bit unfinished when the rest of him is all shiny and new.

For some reason, you can only buy brass bowler hats in one size, 45mm. This is too big for a medium size horse - that's the size that Oliver, the extra-large Stevensons Brothers horse I bought for my daughter when she was small has. So, being a jeweller, I made my own 38mm ones from brass sheet. First I milled it down to 0.4mm thick, cut it into squares, annealed them and tapped them into a doming block. I had to anneal them three times. Then I pierced out a circle, polished them, and drilled three holes in each. They aren't perfectly regular, but will look fine.

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