Workshop Clock Challenge - Part 5
Joining the Dish & Frame
With all the components prepared the final construction of the clock could begin. Firstly, although the wooden former mirror frame fitted over the upturned stainless steel dish, they needed to be fixed together permanently on the reverse. This was achieved using stainless steel screws with large washers, overlapping the edge of the dish.
Bolting on the Fondue Forks
Bolts could now be inserted through the previously drilled holes in the dish in order to hold the fondue forks in place, at their forked ends.
Attaching the Minute Markers
The minute markers were attached to the frame using tiny stainless steel screws. These nestled into small notches filed into the edges, a time-consuming process given that each had three of these fiddly little screws. The result however, is much more satisfying than using adhesive or, more obtrusive fixings (from a design point of view).
Fixing on the Enamelled Elements
Next, the handle ends of the forks were attached to the rim tightly with wire, holding them firmly in the correct hour positions. The enamelled elements could then be joined to the handles of the forks using the same tiny stainless steel screws as for the minute markers. These would be strong fixings while not distracting from the decorative effect.
Decorating the Minute Markers
The diamond-shaped former ring settings were decorated with small, colourful swirled enamelled copper discs. They were created in a hot kiln (800ºC) using a long fine-pointed tool to stir the molten glass. This may sound simple but, the process takes place inside a small box-like chamber with the 11mm discs glowing red hot. Timing is crucial, the glass must be liquid enough to stir, otherwise the disc will simply stick to the tool. It is impossible to know if you have achieved a pleasing swirl of enamel colours until the pieces have been removed from the kiln & cooled. There are many failures.
Final Assembly
The two central semi-circular enamelled elements could now be fixed in place. A copper disc was given a hammered finish (similar to the texture on the rectangular minute markers). Then, a hole was drilled in the centre, and it was placed on top of the enamelled sections. The clock movement was inserted through both the dish and copper disc. I chose copper for its colour (as well its malleability) because it would tie the whole design together with its warmth and similarity to the shade of the wood.
I extended hands made for a battery clock movement to a suitable length for the size of the clock using aluminium. It was necessary to alter the supplied hands, as they have fittings which allow the mechanism work. I had thought black would be a suitable colour for the hands, but they did stand out sufficiently to be effective. I needed to re-paint them, and added a bright turquoise blue mottling, as a final touch.
The Finished Clock
Finally the hands were re-attached and the clock began to tell time with the insertion of the battery.
With a mixture of satisfaction and relief, my 'Workshop Clock Challenge' came to a close, and the clock was mounted on the wall.
It had taken many, many hours to successfully design and construct a clock which brought together very diverse components, which were never intended to be used in this way.
All the while, each of the processes were comprehensively recorded, in words, images & video.
"Enamelling is essentially the art of melting specially made glass powders on to a metal base, in a hot kiln, to create something colourful & beautiful."