Chain Making
Q.I sort of barfed up my first chain by pulling it through a too small hole in my draw plate. It is kinky, uneaven and not as pretty as it was. I am trying to open it up again and make it nice but not sure I am getting anywhere. For my next effort, I would like some opinions before I start another one. I am making the simple Etruscan chain as described in the Complete Metalsmith. What is lacking in the description is any mention of proportion and presume the wire size and ring diameter have some relationship that produces different results. Not knowing where to start, I arbitrarily chose 3/8" diameter rings and 20 gage wire. It is probably pretty subjective but what combination would give the best looking chain?
A.the best ratio is the one that produces the tightest weave, with links closest together. So that translates to the largest wire size, for a give link diameter, that you can still manage to weave. If the wire is too large, then even with a good awl forcing the links open again after threading them into the chain end, you won't quite be able to get the next link through. If it's fairly simple to weave the links, and you don't have to work too much to open the link ends up in order to get the next link through, you can increase the wire size, or reduce the link diameter. The only structure for which I ever determined an actual ratio is the one where the chain links are woven in two axes (two directions, at 90 degrees to each other, of insertion/weaving), and double meshed (each link goes through two previous links in it's axis (each straight, flat link, is inserted through four loops before bending up into the next "U" shape and opening up the ends with an awl). For that one, a ratio of about 40:1 of wire diameter to link circumference seemed about the tightest I could get. As to your messed up chain, first try pulling it back and forth vigorously over a curve that's about as tight a curve as it wants to bend over, such as a bracelet mandrel, or other such smooth steel curved surface, rotating it as you go. this both evens up the amount of "loosening", and burnishes the links down a bit if they're sticking up. If it still is odd, then use a soft (plastic, rawhide, etc) mallet with the chain on a wood or other soft surface, and very gently, while rotating the chain, hammer it back a little tighter, then repeat the limbering up described above. If you're drawing operation actually stretched the wire, then you won't be able to get it quite as tight as it was before, but even so, you should be able to at least get it reasonably usable. The problem you describe, by the way, is one reason why some people use chain drawplates home made of delrin or other plastic, rather than steel. Not aggressive enough to actually deform the wire much, only enough to pack the wires down. and you stop when the chain has packed down tight.
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