Step 1.
After removing the post from the fret, the edges need to be cleaned up.
Secure the etch in the Hold and Fold©, leaving the edge clear of the tool.
Using a file, carefully file away any fret tabs or burrs. DO NOT REMOVE TOO MUCH!!
Repeat the process for the other edge.
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Step 2.
Prior to folding the post, the etched fold lines need to be lightly scored
to assist in the bending process. Using a scalpel or knife blade, and using light finger pressure,
run the blade down the etched fold lines. Generally, two to three passes is sufficient.
Be careful not to cut all the way through the etch.
Sufficient scoring has occurred when a faint line appears on the reverse side to the fold line.
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Step 3.
Making the first fold. Using the Hold and Fold© in the arrangement shown,
clamp the post with the fold line against the edge of the tool head. The fold line should be
aligned so that the it is just visible outside the edge of the tool head. Slide the folding blade
under the exposed etch, gently forcing the sharp edge hard against the tool head edge.
Using even pressure along the length of the fold, (this is especially critical when folding the long posts)
gently lift the folding blade upwards to achieve a 90° bend.
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Step 4.
The first fold complete! Ensure the completed fold is straight
and at 90° along the length of the fold.
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Step 5.
Re-clamp the post as shown ready for the second fold.
Using the same technique with the folding blade as before, make the second fold.
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Step 6.
The second fold complete! Once again ensure the
completed fold is straight and at 90°.
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Step 7.
Re-clamp the post as shown ready for the third fold.
Using the same technique with the folding blade as before, make the third and final fold.
Note that this fold will only be able to be bent to approximately 45° due to the tool head getting
in the way.
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Step 8.
The third fold almost complete!
Ensure this fold is at approximately 45° along the length of the fold.
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Step 9.
The third fold is completed using a solid piece of hardwood timber with a
true surface, pushing against the square edge of the tool head as shown. Note the tool
head has been repositioned on the base. With the post in the position shown, carefully
push the block of wood against the post to complete the third fold. Take care to evenly
bend along the length of the post so the sides meet as close as possible. Don't worry
if you cannot get the sides completely closed, as the final tweaking comes next.
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Step 10.
Your signal post is nearly complete!
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Step 11.
Place the post on a flat surface and using the same piece of hardwood with
light pressure, carefully slide the wood up and down along the length of the post closing the two
sides together. You may need to repeat this on the corresponding side. During
this process, regularly check the alignment and squareness of the sides.
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Step 12.
The completed post ready for soldering.
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Step 13.
After cleaning the post along the join, and applying a suitable liquid flux,
hold the post in some suitable clamps, and apply solder to the join.
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Step 14.
The final step is to clean up the soldered join with a file.
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