I left off fitting the Verge Board to the Top Horseshoe Member.
I started by drilling some holes to attach it firmly, so I could accurately mark the length.
Here I’m putting a mark to indicate the length on each side.
After filing & sanding to length, here it is, fitted in place:
Now, I need to make the rim of the verge board. The rim is a strip that runs all around the verge board. It is 1/8” wide, made from 1/16” brass sheet. The problem is that it’s a ‘little’ bigger than the verge board itself, but needs to fit flush with the edge. So, I rolled the verge board around some and came up with this general shape. I started to mark off the 1/8” width but then decided not to do that till I’d cut out the top profile, as you’ll see.
I started by cutting out the shape on the band saw, leaving a bit around all edges.
Then I shaped the top edge of one side on the disk sander, like so:
And used a divider set at 1/8” to mark the width for the part I’d shaped.
Then cut out the bottom edge using the scroll saw. It goes slower, but it gives me much better control over the cut.
Next, I drilled and tapped some 1-72 holes, for solder holders.
And, holding the rim in place, I transferred the holes to the verge board.
Then drilled them with 1-72 clearance holes.
After attaching the length that I had shaped, I formed the rim around the verge board and marked the rest of the shape up to the sharp bend at the end.
After cutting and shaping up to that point, I held it in place with the existing screws and clamps:
And marked that final piece.
Here’s the final rim piece, shaping complete:
And now, with the trial fit before soldering, I’m ready to go! One thing I found in the trial fit is that one of my carefully marked holes didn’t line up
But it seemed to have a good connection even without that screw so I didn't bother with it and just left it in to fill the hole. (You can see that right at the lower bend in the rim.)
After silver soldering the rim to the verge board:
And finally, after a nice pickle bath and a lot of clean up and filing work to even everything out:
THAT was a lot of work for one little part!
Thanks for taking a look.
Kim
PS. You might note that I've made way more progress in the last few days than I normally would. That's because I got my daughter all married this weekend and now that everyone has left I still have a few days off. So I just had to play out in the shop
How fun is that?!