Cut and texture the copper tubing. Wrap a tape measure snugly around your wrist. Use a tube cutter to cut this length of 1⁄4-in. (6.5 mm) outside-diameter copper tubing [PHOTO 1]. Anneal, quench, and pickle the tubing.
NOTE: If you do not have a tube cutter, you can use a jeweler’s saw with a 3/0 blade to cut the copper tubing. Secure the tubing, and cut slowly to avoid sawing crookedly or breaking saw blades.
Lay the tubing on a bench block, and use the flat side of a chasing hammer to flatten the entire length [PHOTO 2]. Anneal, quench, and pickle. Lay the flattened tubing on the bench block, and use a texturing hammer to add texture to one side [PHOTO 3]. Anneal, quench, and pickle.
NOTE: Feel free to use other hammers or tools to make interesting textures on your tubing, but note that heavy or irregular textures may make it harder to set and rivet your silver wire.
Prepare the silver wire. Cut a 3-in. (76 mm) piece of 10-gauge (2.6 mm) fine- or sterling silver wire. Lay the wire on the bench block, and use the flat side of the chasing hammer to flatten it. Flatten the two ends of the wire so that they are wide enough to accommodate a 14-gauge (1.6 mm) brass rivet. You can either flatten the center section of the wire completely, or leave it with some dimension. Anneal and quench the wire.
Use the ball end of the chasing hammer to texture the wire [PHOTO 4]. Anneal and quench the wire.
Drill holes. Use a permanent marker to mark where to drill holes in the wire, in the center of each flattened end. Use a center punch or nail set to create a divot at each mark [PHOTO 5]. Drill a hole at each divot with a #53 (1.5 mm/1⁄16 in.) drill bit.
Line up the silver wire on the copper where you want the silver to sit. Mark through one of the drilled holes in the silver where you want to drill the first hole in the copper tubing. Use the center punch or nail set to create a divot at the mark, and drill a hole at the divot [PHOTO 6].
NOTE: You will only drill one hole in the copper tubing at this time. This ensures that the second hole will line up properly after the first rivet is set.
Cut the first rivet wire. Use flush cutters to cut a short piece of 14-gauge (1.6 mm) brass wire. Line up the hole in the copper tubing with the hole at one end of the silver wire. Be sure that the textured side of each piece is facing outward. Insert the brass rivet wire through both holes.
NOTE: The rivet must fit tightly in the holes. If it won’t fit, lightly sand the wire, or slowly file the holes with a round needle file until the wire fits snugly in the holes.
Use flush cutters to trim the rivet wire so that approximately 1 mm of brass wire extends on each side of the metal [PHOTO 7].
Set the first rivet. To set the first rivet, use the ball end of the chasing hammer to gently tap the end of the rivet wire from all angles. The rivet will begin to mushroom over [PHOTO 8]. Once it has mushroomed enough to stay in place, flip the assembly over and gently tap the other end of the rivet until it begins to mushroom over like the first side.