Flexible Brass Fish Craft - Ganjam, Orissa
Although the final product might be a fish or a prawn the process in which it is made is the same.
• To begin with first all the calculations are made according to the required size eg: for a 10cm fish 2.5cm is the head and 2.5 cm tail fin so the body would be 5cm. For each inch of the fish 4 body segments are required for smooth flowing movement. So for a body, which is 5cm, it would require 8 segments.
• The brass sheet is then cut into smaller pieces of required length and breadth. This is done very precisely using a divider.
• These pieces are then given a zig-zag or a wavy pattern to represent the scales of the fish. This is done for every segment of the fish using a chisel and a hammer.
• A piece of the brass sheet is made into a conical shape to make the head of the fish. This is done with the help of a metal rod, which is used as a mold on which the brass sheet is beaten.
• The segments of the body are all beaten on the metal rod until they turn into a circle of required size. Each segment is slightly smaller than the one in front of it so that it fits properly and flexes.
• At the end of these brass strips a small paste of the alloy of zinc and tin is applied.
• The rings are then heated in the furnace and the rapidly cooled by dropping them in cold water. As the alloy of zinc and tin has a lower melting point it melts sooner and then fuses back together when cooled. This makes the two ends join perfectly.
• The first segment of the body is placed right behind the head and aligned properly and a hole is mad through both the body segment as well as the head of the fish, on the top as well as the bottom.
• Brass wire is then passed through the holes and is then used to tie the pieces together.
• Holes are then punched on all the other segments including the tail and the brass wire is used tie them together.
• Brass sheet is used to make cut outs of the shape of the fin.
• The sheets are then beaten into proper curves of required depth.
• Designs are then embossed onto the brass sheets.
• The two pieces are then welded together.
• Flat brass sheets are bent in a zig-zag pattern and cut in a curved shape to create all the fins.
• Holes are drilled at specific places wherever required and the fins are attached.
• To give the finishing touch the red eyes are added to the fish. In the case of the prawn brass wire of varying thickness is used to create its whiskers as well as the legs.
Flow Chart:
