Watch Case Progress

Published Feb. 5, 2018, 10:05 a.m.

A Gallery to show the process of discovering how to make a watch case. Very useful for me to see what I did when coming back to this in future.

I'll add more descriptions shortly, there's quite a bit of catching up to do - been busy lately!

Starting with some brass plate Cutting metal from stock Fine adjustment to cut the bar straight Cutting the bar on the bandsaw First bar cut Three bars cut Stake for hammering the ring Hammering the bar into a ring Annealing the bar with a torch Bar cooling a bit before quenching Cutting the ring for a better join Join needs to be closer Getting as close and straight as possible Mixing some borax Degreasing the ring before soldering it Soldering the ring, heating with propane torch Soldering the ring, solder has fused Cooled down after soldering Secure the ring in the lathe Inside of the ring is cut Cutting the outside of the ring, fixture experiment This ring is too large Cut out a section to make smaller Re-solder the smaller sized ring Hammered ring Hammered ring in the chuck Ring cut on the outside, inside and top and bottom Dial shelf cut into the ring Dial set on dial shelf in the hand Dial inside the ring seen from above Dial sat on the dial shelf Making the lugs Setting the angle of cut for the lugs Cutting an angle into the lugs Checking the measurements for the lugs Cutting the grooves for the lugs to go Cutting notches for the lugs to sit Checking the lugs fit into the notches Cutting the notches on the other side All the lug notches are cut Notches cut, top down view Using helping hands to put on the flux Placing solder and flux for joining the lugs Flux dried onto lugs joint Second set of lugs nicely fluxed Set-up for soldering the lugs Ready to solder the second set of lugs Lugs soldered on Making the lugs all the same size Close up of cutting the front face of the ring Setting the angle to cut the lugs on the lathe Lugs cut Underside of the lugs is cut too Flattening the joint to make a good solder joint Flattening the joint by filing Getting the joint as close as possible Joint of the second ring is soldered together Shortening the ring as it's too large Ring with a section removed Ring sections hammered together for a close fit A close up of the join for the second attempt Check the ring size Second attempt at soldering the second ring Ring in chuck with copper shims Cutting the outside face of the second ring Cutting the front face of the second ring Watch glass curvature Watch design plans Cutting out a copper disc 2 Cutting out a copper disc 3 Checking the backlash in the x-axis Checking the backlash in the rotation table Centering the rotation table on the mill table The cut out copper disc 2 The cut out copper disc Cutting holes for screws in middle section Hole size for screws 1 Hole size for screws 2 Cutting larger holes The screw holes for attaching the top section Putting a thread into the top section Top section screwed into the middle section Checking the backlash in the lathe Cutting the top recess in the middle section A close up of cutting the recess space for the top section The recess for the top section cut in the middle section Top section outside fit cut Cutting the joint in the top section Polishing the top piece with wet 'n' dry paper The inside cut tool position on the lathe Setting up the lathe to do the top section cut Polishing with water of ayr stone substitute Making sure the dial is round Checking the dial fits Filing to make a snug fit Looking at the back of the dial through the back of the watch Dial space cut into the top section and fit to the middle Top section and middle section fit with dial Setting up the lathe positioning for cutting the top section Cutting the glass space in the top section Measuring the diameter of the top section glass fit space Front watch glass diameter Putting on marker to help see the cut Radius on the top section is to match the curvature of the watch glass Putting a curve on the inside watch glass shelf Top section inside cut to put on curve g-code for the watch glass shelf curve Top section glass shelf cut Polishing watch glass fit shelf Trying to fit the top glass section Fitting the front watch glass Watch glass fit Top section with the glass fitting nicely front section ellipse curve g-code Cutting the curve in the top section 2 Cutting the curve in the top section Top section with the curve cut, on the table Top section with the curve cut Cutting the gasket recess space in the top section 2 Cutting the gasket recess space in the top section Top section with gasket ring showing chatter Top section with gasket ring Middle and curved top section again Middle and curved top section put together Inside cut of the middle section again Inside cut of the middle section to fit the back section Back section insert shelf done The bar for the back section is cut a little wider Back section ring hammered into shape Flattening the joint for the back section ring Joint for the back section ring Edge view of the joint for the back section ring Back section ring with flux ready to add heat Hot back section after solder melts New back section much wider Inside section to be cut from solid brass Cutting the back section ring on the lathe Shaving one of the faces of the back section Top sections and the back section ring Back section with all the faces clean cut Setting the lathe tool position Cutting the back section for fitting to the middle section Start the cutting of the back section Showing how much needs to be cut off Back section flat watch glass fitting Cutting back the glass shelf in the back section Cutting back the glass shelf in the back section 2 Fitting the glass into the back section Fine grinding back for fitting the glass Back section with the glass fit back ring ellipsoid g-code Cutting the back watch section curve Close up of cutting the back section curve Back section curve cut Base section fit into middle section Gasket fit into the base section Filing curvature into the lugs Filing the lugs to make consistent shape Lugs with curvature Using previous holes to position the piece Drilling holes for the base section fit Middle section with addition pre-tapped holes drilled Centre drill holes in the base section Re-drilling the centre holes in base section Centre drill outide face of the base section Putting a screw recess into the base section Tapping screws in the middle section Tapping the screw holes in the middle section Opening out the lugs Watch constructed with strap just placed in position Making the blind holes with a graver Using a graver to mark the hole position Using a long drill for a flexible drilling shaft Middle watch section with strap holder pins Middle section with the strap attached The underside of the constructed watch The constructed watch with the glass in place Inner section cutting g-code Cutting the inner section Cutting inner section lips Making the inner section circle Grinding with wet 'n' dry paper Checking inner and middle watch section fit Inner section having the top rim trimmed to size Cutting the fit for the back section Sense checking the inner section size Inside section with the top rim profile cut Inner section with top rim cut Checking the fit into the middle watch section Top view of the inside section fit Inner section bottom fit cut Reducing the inner section depth Inner section finished Watch Case with cloisonne frog dial Watch and movement Cutting a square piece of brass from stock Fine adjustments to the four-jaw chuck Set up ready to cut the initial disc Copper strip to cut out the disc Circle marked out ready to cut Gradually cut to a circle Work needs deburring Cutting the face of the stock Circle cut for this side Copper disc Cutting the ellipsoid shape The tool direction set up to cut the ellipsoid Centering the rotation table to drill the hole in the dial The diameter of the movement hand tube connectors Ready to drill Hole drilled Domed disc and the movement in place Movement sits too high on inner section Movement on the inner section Widen out the inside circle of the watch inner section Watch movement too big still Tool position for opening out the inside circle After cutting enough the movement sits deeper in Movement sitting nicely in the inner watch section Copper disc sitting on wet 'n' dry paper Linish the copper dial to make rim flat Sitting better on the inner section Dial sits on movement with no gaps Movement hands sticking up above the dial - just! Top view of the movement in place from the back Movement in place from the back
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