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Old Saddle Catalog Reprints

MAKING ROY ROGERS LIMITED EDITION SILVER SPURS
Step 1: Fabricate the stainless steel blank from one inch wide bar stock. Cut the shank from a plate and saw the rowel slot. Next locate and drill the two holes on each side of the heel band for the swing button brackets and the hole for the rowel attaching pin in the shank. Bend the heel band to approximately 3 1/4 inches across the opening. Finally, weld the shank to the heel band and grin the weld to form a continuous radius at the joint.
Step 2: Cut 20 gauge sterling silver sheet slightly larger than the dimensions of the spur blank using a template that is slightly larger than the finished spur blank size.

Step 3: Clean both the sterling and the stainless spur blank to remove grease and oxidation.

Step 4: Apply solder to both the sterling and the spur blank.

Step 5: Clean both the sterling and the spur to remove all traces of flux residue and file off any high spots in the solder.

Step 6: Bend the sterling silver to fit the side of the spur blank. Make sure there are no high spots in the solder since the high spot will transfer through to the silver overlay when pressure is applied to the silver sheet when joining the overlay to the spur blank.

Step 7: Attach the sterling overlay to the spur blank with clamps and a fire retardant material (mill board) so that there is a tight bond, no gaps. Reshape and contour fit the silver by tapping lightly with a plastic hammer, if necessary.

Step 8: Bring the sandwich of the sterling silver overlay and stainless steel spur blank to temperature with a torch and solder the silver to the spur. Add additional solder to the edge of the sandwich to make sure that there is no gap between the sterling silver and the stainless steel. Allow the sandwich to cool before proceeding.

Step 9: Remove the excess sterling silver from the spur with a jeweler s saw. Cut the sterling silver down to within ~ 1/8 inch of the edge of the stainless steel spur blank.

Step 10: File the over hanging sterling silver flush with the edge of the spur blank. A small belt sander and hand sanding are required to match the edge of the sterling silver with the edge of the stainless steel spur blank.

Step 11: Drill out the holes in the sterling silver for the swing button arm bracket and the hole for the rowel pin.


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