Interdisciplinary Skin Tutorial

Step 1:

Understanding the 3d form:

The model is divided into 2 parts. The head part has an inward curve where the bottom curves outwards. The overall form is similar to a cone. 

Step 2 :

Understanding the tools:

Slip rollers

The roller is used to form the initial cone shape. 

Although it was not recommended during the workshop practical lessons at the beginning of the course, by feeding an angle of the sheet (instead of the edge parallel to the roller) into the roller, the top curve obtains a much smaller radius comparing to the bottom curve. 

The process takes patience and practice since the raiser roller  behind the feeding ones has difficulty biting onto the sheet.

Combination of hammers

(Nylon, hardwood and steel hammers with flat and straight pein ends)

Polished steel dollies

(tapered steel T-dolly, mushroom steel dome and curved steel T-dolly)

Step 3:

Measuring and trimming:

Larger aluminium sheets is cut to a proper size with a sheet metal guillotine and it is then cut into a fan shape with a sheet metal cutter. Then the measuring of the curves are transferred onto the sheet.

Remember to file sharp edges down immediately after cuts !

step 4:

Pushing the material 

More efficient :

Less efficient:

After defining the middle dividing line, there are two approaches. You can either push the metal away from the line or push the it in towards the line. Though I believe both methods would achieve an acceptable at last, the first method is much more efficient. The problem with the second method is that there is no easy way to push in the middle part around the line. Once materials are crumbled together, it is hard to then move it. 

step 5:

Learn to use the hammer:

The key is to listen for the sound when the hammer is hit just a little bit higher and lower than where the straight hit is. By doing so, the material is easily pushed. However, do not hit too far away, then the sheet is bent instead of being pushed. 

step 6:

Defining the line:

By now you should get a form like this. The curves are nicely formed yet the middle line is diminished. To re-define the dividing line, you will need the steel hammer with straight plein end.

Normally it is not recommended to hit the finish side of the metal with a steel hammer, here it is an exception since the hammer mark helps to define the line. The wood angle is relatively sharp so be careful not to over work the metal.

Step 7:

Finishing the surface:

Now lightly hit the metal straight on to the dolly with a flat end steel hammer. The surface will get back its original shine and smoothness. But remember not to hit the metal hard so that you have more control.

You may also choose to use the English wheel but it is not recommend. Even with the roller with the smallest diameter, the curves of this particular model do not fit into the roller without being bent. 

Result:

Summary:

Trying to use a combination of tools is the key here. I'm now a believer of the art of metal working since each and every tool gives a different effect on the metal. Some tools may be faster at getting the job down but may lack finer controls. Again, the metal working process really informs me the importance of the characteristics of a given material, and how a combination of tools the correct method can enhance them.