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Making a Copper Jambonnière Part 3

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If you’ve been following the saga of pattern creation and remaking a vintage piece of copper cookware from scratch…here’s the final conclusion.  Likely you might be as happy as I am that this is done and I can start posting things like cheese recipes again…

So it was time to create the lid and handles to this crazy jambonnière project – finally! As always, it meant a large amount of guesswork, and fiddling with wood jigs.

Tracing the base, we added some fractions to allow for crimp seams, and went ahead to create a cover jig, which was similar, but not exactly the same, as the base jig. I’m learning, in a very tactile way, that should I ever own my own metal shop, I will inadvertently become an ad-hoc woodworker by necessity. We also went ahead and cut out a pattern to make the big top cover.

(Good thing my husband has lately been into buying every kind of saw invented…now I just need to convince him that a drill press is also necessary…)

Next we folded (twice) the band base and linked the two pieces before connecting them with a lap seam and some extra reinforcement pieces before bending the whole long band over the jig. With a little help from a lot of clamps, we finished forming the cover band inside the body to make sure it allowed for any tweaks and idiosyncrasies creating during the bending of the base.

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Creating the jambonniere lid band

Then it was a simple (for once!) practice of burring edges, clamping the cover piece to the band and hammering the seams together before soldering.

We only had maybe…five? ten?…hang-ups along the way… It likely didn’t help that all three of my children are off school and like to create while they’re at the shop with us and are constantly adding some sort of project to get soldered…

But we had a cover that fit, for the most part, so then it was time to form the handles. This is when Bob’s mini forge comes in handy. We fired up the propane (and Bob, bless him, made a sweet little jig for bending), heated up some super fat solid copper wire, and made handles that look very similar to the old photographs.

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Jig for creating copper handles

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Forming copper handles over a jig after blasting with heat.

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Buffing the copper handles

I should mention, as well, that Jan, from the Netherlands, found this blog and was amazing enough to send photos of the jambonnière pan he has in his vintage collection. The cover looks constructed almost exactly to how we did it in our reproduction, though I do covet the base, which looks either rolled to a bead or somehow wired.

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A vintage jambonniere pan – photo sent to us by Jan in the Netherlands!

After getting the handles connected, and folding and creating a simple, thick cover handle, we riveted and checked all the seams, worked together to double bottom the base for strength, and then settled on the final polishing.

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Top handle for copper jambonniere lid.

And suddenly, amazingly, it’s done!

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Finished copper jambonniere ham pan

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Making A Copper Jambonnière Part 2

My ongoing apprenticeship at Backwoods Tin & Copper has been mostly obsessed with finishing up the copper jambonnière pan – not least because we wanted to have it done to show at the tinsmith convergence in Indiana this month.

So the craziness continued.

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Tinning the copper jambonnière in the flat.

After finally creating the bottom pattern that seemed to work, we set about organizing the sides of the jambonnière. Besides knowing they should be about 8” high, we had to figure out a length and a process. This, apparently, was another part where we had to make a few examples and mess up a few  more times.  (I’m starting to realize that creating a new pattern from scratch is about 65% of making copper and tin wares…)

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Preparing the sides for wiring.

Bob finally was able to figure out that putting the wire in when the two sides were joined as a huge circle was the best way to handle it, but that was only after we’d tried to form the sides on the hollow mandrel first, and then wire it. We ended up poking the steel out of the soft tinned copper.

Whoops.

And then there was the math. I’m not very good at math, which is why my husband handles the company accounting for House Copper, etc (thank heaven!) but this tinsmithing math also deals with fractions. Which, to me, is even worse, because they’re never normal fractions – a gripe I often voice when at the tinshop. I believe after Bob tinkered for hours after I left (read: defeated and needing to get my children from school), he ended up with sides that measured 26 5/16”.

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Forming the sides of the jambonnière by hand on the hollow mandrel.

But we still had to free-hand form the sides to match the base, and then create a jig to fit inside the jambonnière base that we then sawed apart and screwed back together in order to create a tight enough structure to allow for seam setting.

We spent more time measuring and creating jigs than we actually did making the base!  But the bottom seam is set, and then we soldered it with a lot of heat.

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Setting down the base seam of the jambonnière

Next will be some time to organize a cover that fits our insane bottom pan shape.

If something ends up measuring something along the lines of 26 15/16” I think I might cry.

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Making A Copper Jambonniere : Part 1

It all started with a book. Oh wait. That seems to be my M.O. But this time it wasn’t one of the Flats Junction novels, nor was it even in English.

Instead, it was an out-of-print tome: Les Cuivres de Cuisine by Jean-Claude Renard, brought to my attention by a fellow copper cookware collector and connoisseur. I’ll call him by his online name, kaleokahu, and I consider him to be far more versed than I am in particularities about vintage wares.

Still, when he showed me the page of the coveted but elusive jambonnière pan, I was excited to realize I could make him the missing piece in his batterie de cuisine. Looking at the photograph, I saw the seams and realized that part of why this particular copperware was so rare is not only the odd shape but the fact that most of them were always made by hand.

Photograph of a vintage copper jambonnière pan from Renard’s book

There’s not a lot of us coppersmiths out there making cookware anymore.

Since then, the hunt for information on the jambonnière has revealed little else. I’ve found one other that looks pressed (instead of hand-formed) with a recessed lid, but as there’s little text on the pan itself out there, I thought I’d explain – in parts as we go – the way we have been making this one for kaleokahu. We know the pan requires a lot of copper, a huge footprint, and likely some tricky double-bottoming and raising of an odd-shaped lid. But it’s also a huge amount of fun to try and re-create something that has nearly disappeared from kitchens today.

What is a jambonnière?  In the words of Renard:

Marmite épousant la belle forme du jambon entier, à fond plat, avec couvercle et deux poignées latérales fixes. Autrefois, lorsqu’on cuisait dans la cheminée, la jambonnière était montée su des pieds en fer.

Roughly translated (and mind you, I have no aid but Google Translate, but I’ll save you that step here) it means that the pan was created to mirror and marry the beautiful shape of the whole ham during cooking.  The pan would have a flat bottom, a lid, and two fixed lateral handles.  In the past, when cooking directly over fire, the ham pan was mounted on iron feet.

First it was a matter of finalizing the dimensions. One other book, French Kitchenware: The Art of Collectibles by Monique Cabré gave a photograph of a less hand-crafted version, but still didn’t give definitive measurements. Kaleokahu has his preferences, but we also want it to look proportionate, plus actually fit an entire ham shank as it was supposed to do. Madame Cabré states in her book that the jambonnière was a pan created specifically for the ham (with leg attached) and that it was “of an imposing size”. She also mentioned the same sturdy handles on two sides of the pan, a heavy lid and that some jambonnière pans would have small legs for placement directly in the hearth. We’re not making legs.

We spent some time with graph paper figuring what made sense and what looked and felt “right” in terms of length. All we knew was we wanted it to be 8” high.

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Final copper jambonnière pattern – let’s hope it works!

As my master smith, Bob, of Backwoods Tin & Copper,  has explained to me, tin and coppersmiths of old do not simply make it easy on themselves. Using a compass, nearly all notches, measurements and arcs were created using that particular tool, which is why the traditional, hand-made jambonnière does not appear to be made of joining two circles of different sizes. When I made such a connection Bob looked at me with a strange sort of grin.

Bob: “Well, it can’t be that easy.”

Me: “What do you mean?”

Bob: “It can’t be that easy. Otherwise everyone would do it. There’s got to be more to it.”

And then he proceeded to add additional arcs to the top of the pattern using an extended compass (this being our third or fourth try on paper) that eventually gave way to the slightly “flattened” look of the widest part of the jambonnière pan.

Me: “Why would they make it harder on themselves?”

Bob: “I don’t know. But it would not be as easy as two circles.”

Me: “Well that’s just crazy.”

We both stared at our paper copy and realized it matched the photograph in both size and squashed-ness.

It was time to make a pattern. We pasted the final graph paper on a piece of tin, glued it down and cut it out. Bob measured the exterior of the shape to get a feel for the amount of copper for the outside and added in for two seams – one at the top and one at the bottom – while I traced and cut out the base itself. Soon we had a lot of copper on the bench which now needs to get tinned.

Unrolling copper sheet

So this week, I’ll be standing over a lot of heat with some melted tin and preparing the copper in the flat before we figure out how to hand-shape the sides over a hollow mandrel. Let’s hope it works. Let’s hope it’s relatively “easy.”

Stay tuned…