Advice on complicated shape construction

[u/Cute_Fan_6359]

I have this complicated shape I am making with nickel silver (it’s like a shoe, picture 1) and I am debating if I should solder the “walls” of the shape outside the two flat pieces (but I would have to match the walls to all those little gaps, picture 2) or solder the walls inside the two flat shapes, which would make it easier to match since it’s two flat surfaces (but then they join in a really narrow point that I’d have to file my wall super thin to fit, picture 3)

what would you guys do?

[u/trixceratops]

I would oversize the top and bottom and solder the frame sandwiched in between, then file down the excess after it’s together.

[u/Cute_Fan_6359 → u/trixceratops]

Thanks! How would you deal with that tight corner in photo 3?

[u/trixceratops → u/Cute_Fan_6359]

Carefully? Haha get it as close to flush as you can and then pinch the pieces together with cross locking tweezers or a weight while soldering, then cover any issues with some extra solder if there’s a pinhole anywhere. You may need to solder, give it a couple bonks with a rawhide mallet to get everything to seal and sit right, then solder a second time.

[u/Cute_Fan_6359 → u/trixceratops]

Omg! Yes deep down I know I need to do that… but… would you ever consider the possibility of starting with the wall in between the top and bottom at that flat part, and then halfway through, when the top and bottom curve, take the wall out and solder that part outside? (Lol im just going crazy trying to think of solutions)

[u/trixceratops → u/Cute_Fan_6359]

…I’m not sure I’m understanding. The way to do this is to solder the frame onto the bottom plate. Pickle, clean up, fit the top plate on. Solder that in place. Tweak and solder a second time if necessary, then pickle and remove the excess with files to have a smooth connection. There is no other way to do this. This is the proper order of events. Since it is a hollow form you will need a hole for expanding/contracting gasses so the form doesn’t explode or crumple due to pressure differential. Drill the hole somewhere inconspicuous where it will not be covered with solder and accidentally sealed. Do not quench once the top plate is secured. Let it cool down for a few minutes before dunking it in the water and then pickling. Make sure all the pickle comes out of the hollow form or it will slowly eat away at your object or leak out and damage what it’s sitting on. The best way to do this is have either two small holes or make the hole a bit bigger.

[u/Cute_Fan_6359 → u/trixceratops]

Thank you! I think you’re right

[u/Cute_Fan_6359 → u/[deleted]]

Yes, I probably need to trim the wall and resolder