Sometimes there are small challenges, such as to solder a railing of 1.5mm brass tube.
Seitengelaender-lang_01 (fspg2)
The special here is the lower vertical sheet metal. It is not soldered to the profiles, but embedded in the middle.
Soldering this part between the posts is unlikely to be very durable in the long term.
Brazing was eliminated because I would probably have received a very wavy result.
Seitengelaender-lang_02 (fspg2)
The 1.5mm brass tube should receive a 1.0mm hole in the middle, on top a 1.5mm rounding for the handrail and below a continuous 0.5mm wide slot.
The cyan ends will be short 1.0mm pieces of wire to get more stability.
Seitengelaender-lang_03 (fspg2)
Seitengelaender-lang_07 (fspg2)
A two-part milling template was produced for 6 identical profiles.
Seitengelaender-lang_05 (fspg2)
Seitengelaender-lang_04 (fspg2)
Into both the upper and the lower half were milled grooves with a 1.5mm ball cutter each 0.75mm deep.
In these 6 profiles were inserted, covered with the upper part. Passer pins and 4 screws held everything in place.
First, the 1.0mm holes were drilled in the middle. Short pieces of wire should prevent twisting during further processing
(probably superfluous as the two parts of the template had already fixed everything).
Now the 1.5mm drill bit for top rounding came, then the slot was milled with a short 0.5mm cutter.
Two of these tiny cutters cracked right at the start, only when I reduced the feed to 10mm / min and dived in several 0.2mm increments, survived the third cutter.
Seitengelaender-lang_06 (fspg2)
Together with the transverse profiles, which were also rounded at the ends in the same milling template, the parts were mounted on a 1.0 mm brass wire tfor testing.
It seems to fit.
Seitengelaender-lang_08 (fspg2)
Seitengelaender-lang_10 (fspg2)
