Files were made by forging a rod or bar of steel to the shape of the file. The forged
blanks were then passed to a file grinder who ground the faces, edges, and tang of
the file to a high degree of flatness and shape. The blanks were then sent to the
file cutter who cut the file teeth using a chisel and hammer on a "stithy."
The base of the stithy shown in the photograph above (actually in Grenoside, Sheffield
- with acknowledgements to Grenoside & District Local History Group) was a solid
block of sandstone, slightly narrower at the edge facing the worker, so that his
knees could rest at either side. In the centre of the metal-edged “anvil” which topped
it, was a recess filled with a block of lead (or “stock”) about 6 inches by 3 inches,
and 1 ½ inches thick, protruding above the surface of the stone (use of lead being
potentially lethal to the filecutter's health). It was on this that the files were
cut, the relatively soft surface preventing damage to the first side when the file
was turned over to cut the reverse side. The file blank was held immobile by straps,
which the cutter steadied with his feet as if in stirrups. Most workshops had long
low windows to throw light on the work area. After dark, paraffin lamps would be
used, but skilled cutters worked almost automatically, not needing to look closely
at what they were doing.
The cutting was done with a short broad chisel - Alfred Sibson Hodgkinson's chisel
being shown above (these pictures courtesy of Susan John) - working steadily down
the length of the file, then turning the chisel through an angle of 90 degrees to
complete the “teeth”. Rasps were cut differently, using a punch which cut each tooth
individually.
Alfred Sibson Hodgkinson’s hammer handle is shown above The hammer had a slightly
curved handle, fixed near to one end of the head. The hammers varied in weight depending
on the type of work, but could be as much as ten pounds. The worker held the handle
near to the head, extending the thumb to steady it. It was not raised high above
the block; the cutting power came from the weight of the hammer-head, not the strength
of the arm. Aiming for a steady rhythm rather than speed helped to ensure precision.
The hammer was a very personal instrument - the 'grip' in the shaft actually being
worn through use.
The cut files were then taken for heat treatment to harden them, after which they
were greased and packed for sale.
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