Thought I’d pass along this little technique.
I’m making a new style of head (from sheet stock.040") that takes
its basic form with a tapered square bezel punch. I was able to get
really clean sharp inside corners (where I really don’t care too
much) but the outside corners remained rounded no matter how hard I
hammered the punch, apparently the flats on the head prevented the
corners from seating fully. To file down the flats until a sharp
corner developed would thin out the metal too much. Hmmm, I want this
thing crisp and thick…I ran a fillet of solder down the inside
corners and repunched the head. The extra metal now inside the head
corners allowed the punch corners to ram the outside of the metal
deeply into the bezel block corners. neat clean sharp
I’m not concerned about solder on what will become the insides of
prongs because I’m having a mold made and then cast in Plat as I
need them. Anyway I thought the basic principle involved here might
have other applications for model making.