Making Copper Rings

by John

When I purchased it, the Mamoli kit of bits for the USS Constitution model had been opened, and it was at least 40 years old. Also, there was no inventory of parts to check whether everything was present.

So, not surprisingly, there were a few deficiencies. Some wood sizes, some metal fittings, and brass rings. Wood can be purchased, although the later purchases often did not exactly match that supplied from Italy. Fittings can be made, sometimes from workshop supplies, sometimes 3d printed with PLA. The PLA fittings were surprisingly strong and accurate, and when painted could not be distinguished from the originals.

Brass rings 3mm OD 2mm ID were supplied, but as I commenced the rigging it was obvious that there would be nowhere near enough of them. Also, the 3mm size seemed too big for some of the applications. And I did not want to wait for replacements to arrive from the Melbourne model ship supplies, or from China.

So I decided to make some rings. I did not have any brass wire the correct 0.5mm diameter, but I did have some 0.4mm dia copper wire. The 0.1mm difference does not sound much, but it does look significantly thinner. Also, the copper wire is quite soft and bends easily, so I wondered whether it would retain its shape under the strain of the rigging ropes. So I made some and tested them.

A spool of 0.4mm copper wire from Jaycar, Wind it around a 2mm drill bit….
Cut along the helix, in this case using nail clippers….
which results in a pile of slightly distorted, open rings…..
…which are then flattened in some smooth pliers, and if necessary reshaped in the drill bit…
…then use them. See the little copper rings on the spritsail spar? About the correct size. And I like the colour.
…and those little thin rings did not open up despite the tension in the ropes.