Sep 1, 2015

Making a natural trumpet by hand (75 Pics)


By on Tuesday, September 01, 2015

What we started with - 5 pieces of brass
Hammering the tubes closed on the steel mandrel
Using a tiny hammer to close up all the holes in the tubes
Soldering the tubes closed
Pulling the tubes through a special machine that makes the tubes the exact diameter needed
Sanding, polishing and scraping the tubes to finish them off

A rare treat - we got to see an original 1719 trumpet that was brought into the workshop to be analyzed and cleaned up by the experts

Annealing the brass to make it easier to work with
Filing down the sides of the bell so they fit together better
Cutting the teeth on the bell
Bending each tooth to facilitate the putting-together part
"zipping up" the bell

All zipped up, pre-soldering

Soldered!

Soldering the garland

Sanding/polishing the ball sleeve on the mandrel

Primary workshop



Bell hammering day!
Hammering the bell: Step 1 - hammer on the anvil (after annealing it to soften it up)
Step 2 - gently take out some dents on the bell mandrel, being careful to not dent the bell more

Step 3 - annealing the bell again...
Step 4 - back on the mandrel to burnish with that big steel rod (burnishing = running the burnisher along the bell to smooth it out some more...quite a process)

Then back to step 1...and keep repeating until the bell takes shape









Filing down the solder
More burnishing...
After some polishing
More polishing...

Burnishing the garland

Soft-soldering on the wire on the garland
Cutting the tube for the bows (the bendy parts) in half
Annealing the tubes
Filling the tubes with a metal alloy called Cerrobend. The metal inside allows the tubes to be bent into shape without ruining them, and the Cerrobend has a very low melting temperature so it is easy to melt out in hot water once the tubes are bent.
Starting to bend the tube...



Burnishing the bows


Cutting the teeth on the garland
Stamping some decorations on the garland
Filing down the teeth for even more decoration
Squeezing one end of the tubes and expanding the other so they fit into each other effortlessly
Adding some decoration to the ball and sleeve
Coming together!


Starting to look like a trumpet!

Fancy ferrules where the tubes meet each other
All done!



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