The movement was measured anew and the case measurements made.
General head-on view of the case with main measurements
Aspects of the side profile, the case is manufactured to size so no movement ring is used. Visible are also the 'snap-on' lip on the case.
Here details of the bezel, with details of the snap on portion, and above the case body profile.
Here I check the plans before starting work on the case.
The case starts from a single billet of bronze.
I mark out one horizontal line through the center of the piece.
Then through a simple square object (here a watch anvil) I position the line horizontally.
Here it is vertical and the spindle is locked.
And a horizontal line is traced. Now I have a line that is centered and has appropriate coordinates
I trace the outer diameter of the case and bezel.
Now I trace another line that is slightly larger in order to give some leeway with the cuts.
I use a simple ruler to mark out the interior area to be milled out (the smallest diameter hole of the case and bezel).
I mark this out on the lathe by hand with the tool bit and hand turning the chuck.
The outer and inner extremities of the case are marked.
Here I am marking out the interior lug space.
The interior of the lugs marked out.
The exterior of the lugs is then marked out.
I check the centering of the case and lugs with a drafting ruler.
Here I trace the outer extremity of the case lugs.
Now I mark out the area of the lugs where they start moving downwards.
The billet is marked out an ready to be cut.
I mill out a series of holes so that I can keep try to reuse the same material from the billet for other parts of the case, such as the crown.
Holes are drilled an I will then use a small jeweler's saw to cut out the central portion.
The back of the billet ready to be cleared of the center.
The billet is placed on a vice to saw out the center piece.
Here with a jeweler's saw clearing the inside portion.
This piece will be kept to create the crown.
The center hole is turned to a perfect cylinder.
The billet ready for the bezel to be cut off from it.
I turn the billet around, and mark a larger diameter ring.
Establishing the depth of the piece to be parted off.
Turning the outer diameter of the bezel.
I keep the outer ring to use the bronze for the buckle and other parts.
A long process of hand cutting this, as a parting off tool is to thick. I need to make this cut .5mm wide.
Some progress after much time.
Continued in the Myford lathe.
After a few patient hours this first ring is parted off.
The case body is faced off.
The side of the bezel is then cleaned off.
Hand sawing the bezel portion off with the thin jeweler's lathe.
Making some progress.
The portion of the bezel parted off.
The billet for the case body is faced off.
The bezel is faced off.
In these next operations I will cut the movement seating on the watch case.
The interior is bored to the smallest diameter of the movement, which is the back plate seen when you turn the watch around.
Then the top movement seating is opened.
Here with the movement plate reversed, the top seating is checked.
After that the middle seating of the movement is turned, here after completing that, I check the required depth of the movement has to sit in the case.
A first look at the movement back in it's future new home.
A look at the three step seating for the movement.
Here I am turning the temporary glass seating for the back see-through crystal.
Checking the seating with a glass. The seating will be finished at the very end of the case manufacture.
Here the case is reversed and is placed on a chuck with 4 independent arms so that it can be perfectly centered when it is reversed. Here I am adjusting the bezel's concentricity.
Here I am turning the top of the case and preparing the snap on seating for the bezel.
Further turning. The interior lip has a particular thickness which will then be refined.
The outer diameter of the turned out ring is the outer diameter of the case.
Placing the bezel on the 4-jaw chuck and adjusting concentricity.
Marking the outer diameter of the bezel.
Turning the opening for the dial.
Not turned all the way, as the piece will be rotated so that a through cut can be made, as is now, the tool tip will touch the chuck.
Aligning the bezel for concentricty.
Further turning the inner diameter opening for the dial.
The inner diameter is further reduced to 31.5mm, which needs to arrive at 32mm.
Inner dial opening reduced to 31.5mm.
Here setting the depth of the bezel convex bevel.
A purposely shaped cutter to create the convex bezel.
The main shape of the bezel is obtained. Further shaping and polishing will take place.
The case interior lugs will be cut out, and rectified.
I start by cutting within roughly 1 to 1.5mm of final value.
Here cut the other side.
However, upon making the second cut I realized I had forgotten to drill the guide holes to be able to cut the metal more easily.
These holes allow a right angle or other stronger angle to be made without damaging the saw blade.
First hole drilled.
then I drill holes on the outside of the lugs.
Arriving at the other side of the case.
Holes drilled, ready for more cutting with the jeweler's saw.
Starting to part off the interior area of the lugs.
First portion of the lugs cut off.
Moving to cut the second set of lugs.
Again, going towards the parting cut.
Second piece is cut off.
Then the rough cuts are smoothed out with the milling machine.
Other lugs receive the same treatment.
Then I place the case back on the vice to manually file the interior of the lugs.
I use a triangular shaped file that allows me to create the interior contour of the lugs.
The interior of the lugs is filed to within ca. 0.5mm. Further finishing will be done once the lug shape is given.
Working on the second set of lugs.
Both lugs interior areas are finished.
The case sides will be cut.
I start making rough cuts as they will be corrected with the milling machine.
One side is ready.
The other side is cut. Cutting bronze is slow going as it reacts better to slow cutting than fast (the same with drilling- it takes very slow drilling speeds instead of faster ones).
Halfway through the other side.
A rather disproportionately looking case, ready for the milling machine.
Creating a purpose built case holder for the milling machine.
Checking fit with the case.
Further cutting of the movement holding cap.
Center drilling of the cap.
It will have a screw that will fasten it to the milling machine table.
The rotary table where it will be fastened to.
The case is fastened and sides will be milled.
The milling of the first side leaves a finish that will be hand polished.
The case will need to be further worked.
A soft holder is made from Acetal (which is a rigid plastic).
Checking the fit.
Parting the holder.
The holder so that the interior of the case is not marred by the lathe chuck.
Ready for mounting on the lathe.
Shortening the lugs.
Lugs shortened, and ready for the profile to be cut.
Cutting the lug profile with a specially formed cutting tool.
The rough lug profile (top portion) is turned.
The case top profile is finished in rough stage, hand polishing and more detailing of sides where bezel fits need to be worked on.
Checking the centering of the threading tool on lathe. The threading tool is reversed for this operation.
The lathe is fitted with change-gears to change the imperial thread to metric.
The case ready to be threaded to accept the bezel.
Threading the case.
Bezel is screwed on instead of snap on. I have chosen this as the bronze is quite soft, and prone to marring when removing, and during testing I remove it quite often.
A view of the case with the bezel on.