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Forging Bronze Links

In this project, I’m demonstrating a worn, organic link design that can be made in any size, using bronze wire with no soldering required. This technique builds on the foundation of cold connections and forging, allowing for endless variations. Tools and Materials: 14-gauge bronze wire for structural links 20-gauge bronze wire for drawing beads and secure connections Vice for stability Forging hammer for flattening wire Hand drill or electric drill with a 1/16-inch bit (or size 52 for jewelry-specific bits) Euro tool hole punch for marking drill points Wire cutters (double flush cutters recommended) Round-nose pliers for shaping links Flux for drawing beads Benzomatic torch with MAP gas for annealing and forming beads Step 1: Cutting and Preparing the Wire Cut 2-inch segments of 14-gauge bronze wire using flush cutters. Ensure a flat tabletop cut to minimize extra filing. Repeat the process until you have at least 10 pieces. Step 2: Forging the Links Using a forging hammer, flatten the bronze wire into a sheet-like form. Bronze spreads easily, creating an organic, textured effect. The first round of hammering spreads the metal, while the second round refines the shape. Expect slight expansion—a 2-inch wire may extend to 2.5 inches when fully forged. Step 3: Annealing for Workability Heat the forged pieces with a Benzomatic torch until they reach a red glow. Quench in water—bronze naturally sheds fire scale, revealing a clean surface. Annealing softens the metal, making it easier to shape and manipulate. Step 4: Shaping and Drilling Using round-nose pliers, form each link into an organic, imperfect loop. Mark a drill point using a hole punch tool to prevent slipping. Secure the piece in a wooden mandrel or vice and drill through the marked point. Use lubrication on the drill bit to ensure smooth drilling. Step 5: Creating Cold Join Attachments Link two pieces together by inserting a 20-gauge bronze wire through the drilled holes. Draw a bead on the wire using a torch, allowing it to form a natural, secure rivet. Alternatively, create a flat nail head for a different finish. Step 6: Finishing and Assembly Repeat the process to create multiple linked sections. The final closure is made using a folded, hammered piece of bronze, seamlessly blending into the design. Clean up rough edges with a jeweler’s wheel and finish with liver of sulfur for a rich patina. Bonus: Twisting Wire for Added Detail Using 20-gauge bronze wire, twist sections using a hand drill for added texture. Anneal and pickle to restore flexibility and shine. Final Thoughts This technique allows for customization, whether as a bracelet, necklace, or decorative chain. The use of cold connections and forging makes it a strong, solder-free method for creating intricate metalwork. + + + + + + + + + + + Intentional Metalsmithing Book: https://www.amazon.com/Intentional-Me... JOTN Gemstones: https://shop.jewelsofthenomad.com/col... Beginners Soldering Video:    • The Art of Soldering Bezels for Jewelers -...   Beginners Silversmithing Video:    • Introduction to Silversmithing- How to Set...   Nomadic Toolkit Free Download: https://susan-lenart-kazmerllc.ck.pag... + + + + + + + + + + +