How to make a brass bird cage dress in twenty-five easy steps

Step 12 Frustrating brassy bits

Once the basic shape was formed, it was time to start bending and placing wire to make the actual cage. I had done some attachment testing earlier to make sure that I would be able to attach the metal properly, however, when it came down to actually doing it on the shape itself, some unforeseen problems arose - it wasn't working at all. Ack!

I tested and tried numerous brazing and soldering combinations in an attempt to find a solution. Alas, nothing was working. It was incredibly frustrating. Finally, a combination of Harris Stay-Clean flux and lead solder heated with a propane torch worked.

Hallelujah! .....and huge thanks to Syd and Steve for their help in figuring that out.

The successful process was as follows: I clamped the pieces together with c-clamps, then used a paint brush to apply the flux, heated the joints with the propane torch and applied the 60/40 lead solder.

Be sure that you're working with clean metal. If it's dirty, it just won't bond properly.

Thus began a multiple week adventure of clamping, fluxing and soldering.

*NOTE* Wear a respirator and gloves when dealing with this stuff. Wash your hands often. Lead in the lungs or anywhere on your skin is no good.