Metal Engraving
some basic tips and general knowledge
This piece is the clutch cover for a 97 HD Sportster. Aluminum is a non-ferrous (fairly soft) metal, making it easy to work with. I started by reading every book I could find at the library (which wasn't much) and watching every video I could find.
The process I used was a basic hammer and chisel, mostly due to cost. Other options range from push engraving (works for softer metals), pneumatic engravers (an air tool that basically does the hammering for you), and using a dremel (I opted away from this because the spinning seems to take away control). I bought two chisels from a jewelry supply company. One FLAT HIGH SPEED STEEL #39 (1 mm), & one ROUND HIGH SPEED STEEL #54 (1.2 mm).
First things first; gotta get a design on the piece that you'll be carving. I used a technique called pouncing (printing onto paper, poking lots of little holes into the paper along the outlines, and then drawing on the paper with something that will go through the holes transferring a dotted pattern on your piece) Note* its important to get your design perfect before you start engraving, because its hard to freehand engrave a design if you're a beginner. I chose a quote from Fear and Loathing in Las Vegas, surrounding the Gonzo Journalism logo.
Its also very important to have a good surface to work on. What worked the best for me, was a cement picnic table in a local park. I put down some rubber shelf and drawer liner to keep the piece from skating around while I was chiseling. Simple but effective.
Basically the process that I developed went like this: Im right handed, so I held the hammer in my right hand and the chisel with my left. I started using the flat chisel since it seamed better at removing large chunks of metal. Holding the chisel at a steep angle, I made one or two strikes to get it to plunge and then quickly flattened out to prevent it from boring straight down into the metal. The hammering has to change depending on what the chisel is doing. For example, to make a straight line I was able to hammer harder and slower, however to make tight curves I would hammer much faster and lighter. (Note* always be hammering) To keep from breaking the tip off your chisel's, always be hammering if the chisel is moving.
After getting the design looking good and all the depth fairly consistent, I went back over all the lines with the slightly larger round chisel to give the valley of the engraved lines a smoother look. I did the majority of this work by simply pushing the chisel through the material, (push engraving) because I didn't want to risk boring any deeper. This is the time to clean up all your lines and curves. Alternate from pushing flat through the already established lines, and cutting out additional material from the side of the lines by pushing the chisel down at a steep angle. Finally I went over all the lines with a scotch bright pad, to knock down the sharp edges, and finished with some MOTHERS ALUMINUM & MAG POLISH. For a little extra effect, I also rubbed some lacquer paint into the relieved lines.
After getting the design looking good and all the depth fairly consistent, I went back over all the lines with the slightly larger round chisel to give the valley of the engraved lines a smoother look. I did the majority of this work by simply pushing the chisel through the material, (push engraving) because I didn't want to risk boring any deeper. This is the time to clean up all your lines and curves. Alternate from pushing flat through the already established lines, and cutting out additional material from the side of the lines by pushing the chisel down at a steep angle. Finally I went over all the lines with a scotch bright pad, to knock down the sharp edges, and finished with some MOTHERS ALUMINUM & MAG POLISH. For a little extra effect, I also rubbed some lacquer paint into the relieved lines.
It may not be factory perfect, but its a hand made part that I can show off on my bike.
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