Sovereignty Module: Spread the Mortar
Complete Trowel and Masonry Tool Making: From Bar to Building Tool
Trowels and masonry tools are essential for bricklaying, plastering, and concrete work. This campaign covers blade forging, tang construction, handle fitting, and specialized shapes.
Chapter 1: Masonry Tool Types
| Tool | Blade Shape | Size | Primary Use |
|---|---|---|---|
| Brick trowel | Triangular, pointed | 10-12 inches | Spreading mortar, laying brick |
| Pointing trowel | Narrow triangular | 5-7 inches | Filling joints, detail work |
| Margin trowel | Narrow rectangular | 5-8 inches | Tight spaces, scooping |
| Plastering trowel | Large rectangular | 11-14 inches | Applying plaster to walls |
| Float | Rectangular, flat | 12-16 inches | Smoothing concrete, plaster |
| Jointer | Curved or V-shaped | 6-8 inches | Shaping mortar joints |
| Brick hammer | Chisel + hammer head | 10-12 inches | Cutting and setting brick |
Chapter 2: Brick Trowel Forging
Brick trowel: 1) Start with medium-carbon steel plate (1045). 2) Plate: 4 x 12 inches, 1/16-3/32 inch thick. 3) Cut triangular blade shape (pointed at one end, wide at other). 4) Forge tang: draw out narrow section from wide end. 5) Bend tang upward (offset from blade plane). 6) Tang angle: 15-20 degrees above blade. 7) This offset allows knuckle clearance when spreading mortar. 8) Forge slight dish (concavity) in blade for carrying mortar. 9) Grind edges smooth. 10) Polish blade surface (mortar releases easier from smooth surface).
| Dimension | Brick Trowel | Pointing Trowel | Margin Trowel |
|---|---|---|---|
| Blade length | 10-12 inches | 5-7 inches | 5-8 inches |
| Blade width (max) | 5-6 inches | 2-3 inches | 1.5-2 inches |
| Blade thickness | 1/16-3/32 inch | 1/16 inch | 1/16 inch |
| Tang length | 4-5 inches | 3-4 inches | 3-4 inches |
| Tang offset | 15-20 degrees | 10-15 degrees | 10-15 degrees |
| Handle length | 4-5 inches | 3-4 inches | 3-4 inches |
Chapter 3: Plastering Trowel
Plastering trowel: 1) Start with spring steel plate (1095 or stainless). 2) Plate: 5 x 13 inches, 1/32-1/16 inch thick. 3) Blade must be very flat (no dish). 4) Blade must flex slightly (spring steel). 5) Mount handle on back of blade (centered). 6) Handle bracket: forged steel bridge riveted to blade. 7) Wooden handle attached to bridge. 8) The thin, flexible blade allows smooth plaster application.
Chapter 4: Jointer and Specialty Tools
| Tool | Shape | Material | Use |
|---|---|---|---|
| Concave jointer | Half-round rod, bent to S-shape | Mild steel | Concave mortar joints |
| V-jointer | V-shaped rod, bent to S-shape | Mild steel | V-shaped mortar joints |
| Flat jointer | Flat bar, bent to S-shape | Mild steel | Flush mortar joints |
| Tuck pointer | Narrow flat blade | Spring steel | Filling narrow joints |
| Brick set (bolster) | Wide chisel | Medium-carbon steel | Cutting brick |
Concave jointer: 1) Start with 1/2-5/8 inch round bar, 8-10 inches long. 2) Flatten one end slightly (handle area). 3) Bend into S-shape or offset shape. 4) The round surface of the bar shapes the mortar joint. 5) Different bar diameters produce different joint profiles. 6) Polish the working surface smooth.
Chapter 5: Handle and Finishing
| Handle Material | Shape | Attachment | Comfort |
|---|---|---|---|
| Hardwood (walnut, maple) | Turned or carved | Tang through handle, peened | Excellent |
| Leather wrapped | Over tang | Stacked leather washers | Good |
| Rubber/cork | Over tang | Friction fit or glued | Good |
| Plastic (modern) | Molded | Over tang | Varies |
Handle fitting: 1) Drill handle for tang (slightly undersized). 2) Heat tang and burn into handle (tight fit). 3) Or drive tang into drilled hole. 4) Peen tang end over washer (locks handle). 5) Handle should be comfortable for all-day use. 6) Slightly bulged shape prevents hand fatigue.
Reference Card
- The tang offset is essential (the bend between blade and tang raises the handle above the blade plane; without this offset, the mason's knuckles drag through the mortar). 2. Polish the blade surface (mortar releases cleanly from a polished surface; a rough surface causes mortar to stick and drag, making it difficult to spread evenly). 3. Slight dish carries mortar (a subtle concavity in the blade allows the trowel to carry a load of mortar from the board to the wall; a flat blade cannot carry mortar). 4. Spring steel for plastering trowels (a plastering trowel must flex slightly to follow the wall surface; rigid steel cannot produce a smooth plaster finish). 5. The brick trowel is the mason's primary tool (a skilled mason uses the trowel for spreading mortar, cutting brick, tapping brick into place, and cleaning joints; it is an extension of the hand). 6. Jointers shape the finished joint (the mortar joint between bricks is shaped by the jointer for both appearance and weather resistance; a concave joint sheds water better than a flush joint). 7. Quality steel resists mortar corrosion (mortar is alkaline and corrosive; quality steel with a polished surface resists corrosion better than rough or low-grade steel). 8. A handmade trowel is balanced to the mason's hand (commercial trowels are one-size-fits-all; a handmade trowel can be sized, weighted, and balanced for the individual mason's preference).