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BruceH writes:

The problem: I needed a bail ASAP for some period campaign
chest hardware and there was none to be found anywhere.
Casting would take too long and was beyond my skill level.

The solution: Make my own out of flat bass plate.
You know that drawer or box you throw all your scrap brass in?
Well mine just happened to have a piece of stock the right thickness
that someone once used as a brace on a chair.
Never throw anything away!

Here is the blank after I cut it out on the band saw.
Be sure to wear ear and eye protection.

Next, I filed and shaped the blank a little at a time.
Finally found the perfect job for the Drumel Tool !

Filed, shaped and sanded. Filed, shaped, sanded and trial fit.
Removed the fine, nail like pins that held the original handle in place,
inserted the new handle and used the original pin holes as a guild
to drill the new holes in the new handle.

Here is the new handle installed in its backing plate and colored to
blend to the other one on the same drawer. The new bail is on the right.

I used heat, ammonium and a product called "Blacken It"
to "age" the new handle. Finally, I used color paste wax
to dirty up the recessed area behind the handle.
Let the wax dry without buffing so it would dry matt.

Here is the completed piece installed on the drawer.

Bruce Hamilton
West Newbury, MA