I tried stick welding but even at the lowest arc current of 20amps it was too easy to blow through the 3mm stainless wire - I would expect TIG to be more controllable. I expect the commercial assemblies are cross wire resistance welded but I don't have access to such equipment. Gas brazing was a bit more successful but only after I got some flux intended for stainless steel as the chrome content produces oxides that the regular fluxes won't remove and then it doesn't flow. However the best results so far are using silver soldering with a 440 flux coated silver solder and HT5 flux powder from CuP Alloys. The required temperature can be achieve with a decent butane torch rather than the hotter MAPP gas torch and there is much less discolouration and potential distortion of the wire. Also gives more chance of adjusting things if the alignment isn't right first time. :
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I've made a template of the finished wireform that I can use for bending the wires but I'm still wrestling with how to jig the parts for the assembly process. I've made some pieces that can be used to wedge the wires against the rings from the inside either side of the rings, but currently looks like it would need a couple of well trained octopuses (octopi ?) to hold it all together! Suggestions always welcome.
