cutaways
To Dave,
regarding the cutaways.......
I have a small lathe and a milling machine, that's all what I have on machinery. If I do cutaways, I have to disassemble the fuze in all its parts. After this the most important thing is, to know, how this fuze operates and works and which detail I want to show (or what is important for functioning to show). Cutaways I do for the Federal Government are different from the once I do for myself. They don't need the details f.e. gear cutting of the clockwork. They need to know, how and where the striker is located, the primer etc..
The next thing to do is starting with the fuze housing on the mill, whereas it is an easier task if you just have some centric movable parts in the fuze, or you need to cut off the body at different angles or sides. After this it is really a milling work and trying- -take out, assemble the internal parts, take it back on the mill etc. When the body is done, I start with internal parts or compounds and I just fit them to the body during the milling process. Very delicate pieces I cut off by hand (saw) or with the Dremel tools. After all the parts are ready, I take the "good old file" put fine sandpaper with chalk on it and smoothen the surface of the cut metall pieces to get a smooth metal surface. After that I re-produce the detonators by solid copper pieces or aluminum pieces (dependent on the orig. deto materials.) All explosive - and booster charges and lead-ins and -outs are replaced by wood pieces I make to fit on the lathe. They get painted afterwards. If all the bits and pieces are finished I assemble them back together by using the instant second or 2-compound glue. The last thing to do is finish them off with a good satin clear paint, which should not age, crack or get a yellow tone, even after years. For a more complicated fuze I need 1-2 days, for easier once approx 1/2hour - 3 to 4 hours. Finally you have to excuse my "easy language" since I'm still a German with US-citizenship.
Mrfuze, USA