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Making a mold/mandrel for bow guard

859 Views 8 Replies 6 Participants Last post by  simso
I have this Buffet tenor from 1877 that I'm restoring:!

I've just fixed the dent in the front.
Now I need to re-shape the bow guard. I've managed to get it alright but need to make a mold/mandrel to get a smoother and completely symmetrical shape.
I assume that sugru is too soft (I've never used it). Does anyone have any suggestion on how to make some sort of mandrel for hammering/ironing?
The part of the bow guard that wasnt dented is in perfect shape and I'd like to make a mold from that part and make a mandrel.

I might have to make another bow guard though, as this one has already cracked on a couple of edges from when it was dented. But I'd prefer to keep this saxophone 100% original due to it's historical value! So any ideas and hints are greatly appreciated!

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I'd use a thick piece of firm urethane under it, and use a variety of plastic or wood drifts shaped like a cone with a rounded tip, and very very very gently gradually bring it back to its original shape by tapping from inside with a hammer, using the drifts (you will probably want to have more than one). You'll have to frequency test fit it to the bow part adn be real careful not to overstretch the material in the other direction.

This kind of stuff is why I no longer attempt to do auto body work.
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