ladder pattern fuller

[Dan Graves]

I made a ladder pattern fuller using 3/16 rods and welded them on a 1/4" plate and did another the same and attatched to a fuller where the rods fit into each other when closed. When used they make the billet accordian then I grind and get the ladder pattern. They seem to far apart after it is all forged flat. How can I get a tighter ladder pattern? It seems that when you forge th billet flat it will always make the pattern larger.

[Ed Caffrey]

When using fullers to put a ladder pattern into the blade, it's best NOT to reforge it flat, but rather to grind all the "waves" out of the blade. By doing it in this manner the pattern will go all the way through the blade. Generally you will see fullers of this nature used on presses. In order to get the ladders tighter you will have to go with smaller rods (like 1/4") and space them closer together on the fuller/die. The reason your pattern is spreading out is because you are forging the billet out flat after the fullers are hammered/pressed in. ~~~~~~~ if you imagine those lines all attached and then you flatten them out, they will lengthen making the pattern looked stretched.

[rhrocker]

What Ed said. Also Dan, you can move the 3/16th's rods to where they are more 3/16th's center to center, instead of what you have now which is 3/16th's edge to edge. This way, the two plates will not fit together like the way you did it, but you'll still get a pattern when pressed, then grind.

[Dan Graves]

Thanks guy's for the info. Ed, I read in another post about the 2 methods of patteren development, mech. or stock. It seems that there is no way to make patterns without removing metal (Broad statement). Are there any patterns that can be done (other than twist) without removing metal, ie. using fullers etc.?

[Larrin]

Originally Posted by Dan Graves

Thanks guy's for the info. Ed, I read in another post about the 2 methods of patteren development, mech. or stock. It seems that there is no way to make patterns without removing metal (Broad statement). Are there any patterns that can be done (other than twist) without removing metal, ie. using fullers etc.?

It's called random pattern. Mosaic patterns done in a loaf don't have to have material removed (at least not to the effect you are talking about.)

[schwarzer]

In the early years before power hammers and presses were common in every shop. Random pattern blades were a lot more interesting. Hand work made the layered material move in many different directions. You can replicate this process by using a die with several ball bearings attached . work the bar in several different directions befor forging it to final shape.
It is possible to use laddering dies for a great efect using this same tecnique. I made some really cool pattern using a star geart out of an old piece of machinery. Try using a ball pean hammer under the press or power hammer to start. Be careful usinf hand tools under power equipment is very dangerous.

You could also try forging the billit square then upsetting it on the bias. Repeat this process three or four times it make for very interesting material