Of all the skills you will learn in jewelry making, one of the most enjoyable but also frightening is soldering. The key to beautiful solder joints is a combination of the proper heat and preparation, not force. Start by making a simple butt joint. Cut two pieces of sterling silver wire or sheeting to about 1″ each. File the ends so they are flat and meet evenly, with no space in between. Clean the ends with a fine emery board or with pickle to remove oxidation and oils.
You won’t be able to solder dirty metal and will likely end up with a weak or lumpy joint. Create a small soldering area using a charcoal block or honeycomb ceramic. Place the two pieces of silver together, side by side, on the block and hold them in place with binding wire or third-hand tweezers. Place a small amount of flux on the joint. Using tweezers, place the smallest possible pallion of easy or medium solder on the joint. Many new students use too much solder, believing that the more the better, the stronger the joint.
This will only create solder “balls” and “runs” that will require extensive filing, and can ruin delicate filigree work. Use the smallest pallion you can. It should be just larger than a pinhead. Trust that the capillary action will draw the solder into the joint. Use your torch to heat both pieces of metal evenly, rather than concentrating the heat on the solder. Move the torch around the joint in a steady circle, keeping the torch tip far enough away from the silver to produce a soft blue flame.
As the silver begins to melt, you will see a bright shine over the area. Remove the heat as soon as the solder melts and turns to a bright flash. Practice making simple butt joints in 10-15 minute sessions. Prepare three or four joints, flux, add the smallest amount of solder possible, and solder. Quench in water when cool. After each joint, examine the joint under magnification. If the joint is smooth and shows no “balls” or “gaps” in the solder, note any difference you felt in applying the torch, the distance from the flame, etc.
With repeated practices, you will begin to “feel” when the solder is flowing properly. Your flame will become steady and smooth, the solder will flow into the joint in a predictable manner, and you will quit using too much solder. Your joints will be strong, invisible, and able to withstand the filing and shaping of the metal, and will remain secure during wear. This will enable you to move into more complex pieces that incorporate multiple joints, such as bezel setting, chain making, and multi-part pendants. Be sure to regularly return to simple butt joints as you practice other techniques. The security of beautiful, clean solder joints will allow you to design with confidence.