I have had a few requests to explain this method of forming metal, so I'll try it here.
first you have to saw out the shape you want to form from plexi-glass.

Then you sandwich the metal you want to use between the plexi-glass die and a sheet of urithane.

If you want to engrave the part, do it before you form it. Just trace the shape onto the metal and engrave it flat. The forming will not distort your engraving.
Now smash the snot out of it in your press.

When I am forming an engraved part, I tape the metal to the plexi-glass with some masking tape to be sure it dosen't move.
Now you have the finished part and all you have to do is saw it out with your jewlars saw


You can do this with any part that you want to dome. If you want the dome higher, make the die thicker. If you want a flat top, make it thinner. This is how I make conchos and dome buckles, or anything you want to give some shape.The place to buy the urithane and other components is Bonnie Doon Mfg. I think Rio Grande sells their stuff too.
Jim

Jim,

First let me say GREAT POST! Now the real questions start.

Is the shape you cut out of the plexiglass just a squar cut (flat inside edges) or did you taper the bottom edge that sits on the urthane to give it a (rolled edge) radius?

In this particular example what material thickness was used in each of the three layers?

What was the thickness of the die compared to that of the finished part?

_________________
Billy & Amber Dodson.
BAD Western Wurks.
Geronimo,Tx.

I cut the plexi-glass square. You still get a tappered affect because the copper dosen't get forced clear to the edge. Maybe it would with softer urithane. They have different hardnesses and I'm sure the act different.
The urithane I have is about 1/2" thick, The plexi-glass is 1/4", and the copper is 18 ga. The hood ends up about the same height as the die is thick.
Jim

Jim,

Thanks for the info!....

_________________
Billy & Amber Dodson.
BAD Western Wurks.
Geronimo,Tx.

Great post Jim, I used to use plexi but I found it was a real pain to cut patterns into and after a few pressings it would kill the edges, so I started using aluminum sheet instead for my die's. It cuts really easy "no melting behind saw blade" and the edge's stay true and crisp after many pressings. I just go to my local machine shop and get there scraps so it's pretty cheap. Bonny Doon is no longer in the retail sales business, Rio Grande is now the supplier for there stuff.
Mark

Thats a great idea. Thanks
Jim