When a solid cross-head is not used, but a steel casting, as shown in Figs. 89 and 90, p. 89, or when a shank is not cast to the cross-head and drawn down, Fig. 245 shows the hammer blocks used in forging an ordinary piston-rod, which shows clearly the mode of manufacture. Fig. 246 gives two views of the spring buckles, the first forging and its block being shown in Fig. 247. They are worked out of a piece of best iron 8 inches square, then set down upon each side of the boss for the pin until prepared for the block, in which they are then stamped. Afterwards the flats are drawn out, bent and welded up. The only forge work that now remains is the slide bars, which are roughed out 4« inches square and 2 feet long, then re-heated and rolled in a 14-inch merchant mill to 3¬ by 2¬ inches and cut to 4 feet 3 inches long. They are then set under a hammer after being straightened whilst hot on the floor plates, ready for the milling machine. The whole of the forgings described, are made and finished in such a manner that there shall be a minimum amount of finishing tool work required, consequently entailing a maximum despatch in the machine shop and reducing the cost They are also stamped with distinctive marks, which are carried forward in the machine and other shops.

This system is almost universal, so that in the event of failure of a tire, crank, rod, or any other piece of mechanism its history can can be clearly traced. Moreover, the collection of templates and gauges is constantly kept up to standard, and all forgings worked to these templates. Mandrils and finished forgings are kept purposely for striking swages from, so that indifferent work shall not be possible through lack of convenience in replacing damaged blocks. One mandril may be made up, representing two or more forms of straight axles thus, Fig. 247a, showing a three-standard mandril, each section being turned up, whilst another may have the crank pin ends of the coupling rods. After the swage has been struck, a hole is generally punched at the end or side, and a bar from « to 1¬ inch diameter inserted, which is gripped by the cooling and contracting swage, or pieces to form handles are sometimes dabbed on, and afterwards, if it is necessary, the impression formed by striking the swage is finished by a fitter chipping it up, or otherwise perfecting. If the swage is to be of the clapper type the bows are simply welded on; and finally, fixed blocks are more conducive to good and rapid working than loose ones. An example of this class may be taken in the coupling rods, Fig. 227, one end of the block having that portion marked A, whilst the opposite end swages the centre joint of the rod B, with a good true surface in between for drawing down the rod, having the required radius at the edges. The work is also carefully portioned out, each hammer having essentially nothing beyond its power to deal with, for reasons already put forth earlier in this section, and also retaining its set of men, shingler, furnacemen and helpers, for division of labour is to a great extent answerable for the successful working of a forge.

Fig. 245.

Fig. 246.

Fig. 247.

Fig. 247A.