06/28 Marriage of Metals - Puzzle Fitting

Saturday, June 28, 2025
10:00am - 2:00pm PDT

Instructor: Jennifer Stenhouse

Marriage of metals is a series of techniques that include some amazing ways to combine different alloys of metal, taking advantage of the various colors, to add patterns that can be a unique and beautiful addition to your work! This workshop will focus on a technique called “Puzzle Fitting,” which uses different alloys of sheet metal to create fascinating and planned patterns for sheet stock that can be used for all types of jewelry. Students learn how to start work with sterling, fine silver, copper and copper alloys (like shibuichi, or shakudo), or nickel sheet. We will begin with a small black and white (positive/negative) image and two different color metal sheets of the same gauge. Instruction will include information that will familiarize you with how to transfer a planned pattern image, using 2 pieces of different color sheet metal, through sawing, soldering, filing, and hammering.

Students will learn through instruction, demonstration, and practice the techniques using sheet metal to construct sample sheet stock pieces that can be used for all kinds of jewelry & wearable art. The focus will be on the steps of development to create an image and patterns. Also, the proper use of tools, hammers, rolling mill equipment, patinas, and finishing techniques.

All levels

All classes include the video recording, which you will have access to for 60 days after the class. The Zoom link, handouts, video(s), and other important information can be found by clicking on the individual class link on the "My Courses" page. The Zoom link and handout (if any) will be available 24 hours before the class starts.

You also get 1 free session of Open Studio Access (OSA) in the month following your class, the Zoom link can be found on the course video access page.

The class supply list is below and contains links to buy the supplies you need.

Supply List for Students

The links below will take you to RioGrande.com or other suppliers. To see prices for precious metal items, you need a free Rio Grande account. Students in the Rio for Schools program enjoy wholesale benefits for six months (instructor code = RFSLMF). This site may contain Amazon and other affiliate links. If you purchase something through the link, at no cost to you, we may receive a small commission on qualifying purchases.

Recommended Materials:

You can use all the same gauge sheets of fine silver, sterling silver, copper, and copper alloys, nickel, or if you have scrap or old gold jewelry. I recommend 18 or 20 gauge. You can also use square and rectangle wire of the same gauge or heavier for borders and accents. Contrasting colors can be the best way to learn the process. It makes them easier to see. This can be a fun way to reuse scrap material. You will also need wire hard solder. You can use alloys of solder for silver, copper, or yellow metals like brass or bronze for additional color in the lines between your cut-out parts.

Sheet Metal

Have at least two pieces of the same size and gauge of sheet metal to work with. I recommend 18 gauge, (or 20 minimum.) If you have heavier sheet you can always mill them down to match. You will be doing some hammering and filing during this process so don’t start too thin. Sterling and fine silver will patina differently giving you subtle variations in color, a copper alloy like shibuichi and silver will produce a stark contrast when patinated.

Solders

• Hard silver solder, several feet, (at least 3 feet.) You will be flooding the wires to join seamlessly and using as an additional color.
  
• Medium silver solder 20ga wire
  
• Yellow silver paste solder, good, less expensive option and an additional color.
  
• Yellow silver solder
• Bronze solder
  
• High copper solder
  

Glue

• Super glue
• Rubber cement

Patinas

• Baldwin’s Patina
• No Name Patina Prep
• Liver of sulfur or a sulfur-like product (29% Calcium polysulfide works great)
• Heat
• Rokusho patinas. These work very well when you are combining Japanese alloys like shakudo and shibuichi.
• Flux
• Paste Flux (Ottoflux, or a Borax and water-based flux)
• Stop-ox II from Rio Grande. This is water soluble and non-flammable. I have a small spray bottle from the drug store I use to spray it onto the items before soldering.
  

Items from the hardware store

• Emery paper, 200/400/600 or sanding blocks
• Hammer
• Center punch/scribe
• Safety glasses
• Brass wire and rod
• Heavy hand file
• Rubber mallet

Other tools that are helpful

• Clean flat soldering surface
• Jewelers saw blades 4/0 or 2/0
• Jewelers saw frame -110039
• Planishing Hammer with a ball peen end
• Heavy duty hand file
• Belt sander or rotary sanding drum for the flexshaft
• Satin-finish fiber finishing wheels
• Rolling mill