Brass Chain-link

This project explores how a simple shape can be abstracted into a new form. The resulting chains are tricky to replicate at first, but once the construction is understood, the resulting links should become identical. I made them in brass as a low-cost material, though the design could be produced in any other metal.

In this project we will use mostly basic jeweller's tools:

1. Ruler (steel with notches)
2. Caliber
3. Jeweller's scribe for marking metal
4. Jeweller's saw + saw blades
5. Files for touching up edges
6. 1mm drill
7. Gas torch
8. Solder
9. Rounded steel anvils (sizes 8 through 11 for this project)
10. Hammers

As for materials, I used a 1mm thick brass plate.

Mark on your plate the desired width and length of the chain link. Take into consideration that the length will directly influence the size of the loops. For the design shown I marked 40mm x 10mm rectangle with inner lines spaced 2.5mm apart as shown above. The rectangular hole in the plate (denoted by X in the example) is cut and filed so that later we can saw along the lines more accurately. It is crucial that the lines are cut evenly otherwise the sides of the chain link will be jarringly thin or thick ruining the consistency of the chain.

Anneal the metal after sawing the innitial shape to allow maleability. Afterwards lightly push against the 'prongs' upwards. File the edges of the inner link and the sides of the prongs until the saw marks are smoothed.

Start bending the frame of the link on a rounded anvil. I suggest starting with a larger anvil and gradually transitioning to the desired size. Once the frame is rounded, hold securely and file the seam with a saw to even the edges. If possible, sand down the frame with a sandpaper mandrel for an even finish inside and out.

Press the prongs around a large rounded anvil gently hammering the edges (in this case I used size 11). If needed, anneal the metal before hammering. Saw off any overlap between the prongs and solder the edges together, making a teardrop shape.

Through the slit of the rounded frame thread the loop of another chain link and pinch the slit closed. Optionally, solder the slit and sand off any excess material. Repeat until the chain is complete.

After assembling the chain, I put it through sandblasting giving a rough and matte finish. However, you can choose however to clean and polish.

Thank you for reading ✌️